safety study material

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UNIT-IV

SAFETY IN MATERIAL HANDLING

I.AS/RS SYSTEM

An automated storage and retrieval system (ASRS orAS/RS) consists of a variety of computer-

controlled methods for automatically placing and retrieving loads from specific storage locations.

[1] Automated storage and retrieval systems (AS/RS) are typically used in applications where: there is a

very high volume of loads being moved into and out of storage; storage density is important because of

space constraints; no value adding content is present in this process; accuracy is critical because of

potential expensive damages to the load. AS/RS can be used with standard loads as well as

nonstandard loads.[2]

]Overview

AS/RS systems are devices designed for automated storage and retrieval of parts and items in

manufacturing, distribution, retail, wholesale and institutions. They first originated in the 1980s. [citation

needed] They are compact units that utilize the unused overhead space of a plant or warehouse, and

convert to live storage of product. Items can be placed on trays or hang from bars, which are attachedto chains/drives in order to move up and down. They focus on bringing "goods to the man" rather than

manual walking and searching. Space savings, increased productivity/reduced labor, increased

accuracy and reduced inventory levels are some of the primary benefits. Ideal forlean

manufacturing,sustainability,Six Sigma,Kanban, JITand other value added methodologies and

processes. The equipment required for an AS/RS include a storage & retrieval machine (SRM) that is

used for rapid storage and retrieval of material. SRMs are used to move loads vertically or horizontally,

and can also move laterally to place objects in the correct storage location.[3]

The traditional vending machine is the most common and familiar AS/RS system but because theapplication is to do with retail sales, the logistic concept of a vending machine is missed.

The trend towards just in time production often requires sub-pallet level availability of production inputs,

and AS/RS is a much faster way of organizing the storage of smaller items next to production lines.

Traditional high bay warehousesare designed with pallet storage in mind, and if goods are being

delivered in sub pallet quantities, high bay warehouses are problematic.
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Material Handling Institute of America (MHIA), the non-profit trade association for the material handling

world, and its members have broken AS/RS into two primary segments: Fixed Aisle and

Carousels/Vertical Lift Modules (VLMs). Both sets of technologies provide automated storage and

retrieval for parts and items, but use different technologies. Each technology has its unique set of

benefits and disadvantages (like everything in the world). Fixed Aisle systems are characteristically

larger systems whereas carousels and Vertical Lift Modules are used individually or grouped, but in

small to medium-sized applications.

Fixed-aisle AS/RS is categorized into three main types: single-masted, double masted, and man-

aboard. Most are supported on a track and ceiling guided at the top by guide rails or channels to ensure

accurate vertical alignment, although some are suspended from the ceiling. The 'shuttles' that make up

the system travel between fixed storage shelves to deposit or retrieve a requested load (ranging from a

single book in a library system to a several ton pallet of goods in a warehouse system). As well as

moving along the ground, the shuttles are able to telescope up to the necessary height to reach the

load, and can store or retrieve loads that are several positions deep in the shelving. A semi-automated

system can be achieved by utilizing only specialized shuttles within an existing rack system.

To provide a method for accomplishing throughput to and from the AS/RS and the supporting

transportation system, stations are provided to precisely position inbound and outbound loads for

pickup and delivery by the crane.

In addition, there are five types of AS/RS devices called Unit-load AS/RS, Mini-load AS/RS, Vertical Lift

Modules (VLMs), Horizontal Carousels and Vertical Carousels. These systems are used either as

stand-alone units or in integrated workstations called pods or systems. These units are usually

integrated with various types of pick to light systems and use either a microprocessor controller for

basic usage or inventory management software. These systems are ideal for increasing space

utilization up to 90%, productivity levels by 90%, accuracy to 99.9%+ levels and throughput up to 750

lines per hour/per operator or more depending on the configuration of the system.

]Advantages

An effective automated storage and retrieval system provides several benefits forsupply chainmanagement:

An efficient AS/RS system helps companies cut expenses by minimizing the amount of

unnecessary parts and products instorage, and improving organization of the contents of a

warehouse. Due to automated processes, it also allows for more storage space due to high-density

storage, narrower aisles, etc.[4]

Automation reduces labor costs while lowering workforce requirements and increasing safety.[5]
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Modeling and managing the logical representation of the physical storage facilities (e.g. racking,

etc.). For example, if certain products are often sold together or are more popular than others,

those products can be grouped together or placed near the delivery area to speed up the process

of picking, packing and shipping to customers.

Enabling a seamless link to order processing and logistics management in order to pick, pack,

and ship product out of the facility.

Tracking where products are stocked, which suppliers they come from, and the length of time

they are stored. By analysing such data, companies can control inventory levels and maximize the

use of warehouse space. Furthermore, firms are more prepared for the demands and supplies of

the market, especially during special circumstances such as a peak season on a particular month.

Through the reports generated by an AS/RS system, firms are also able to gather important data

that may be put in a model for it to be analyzed.[6]

Man-aboard AS/RS

A man-aboard AS/RS offers significant floorspace savings. This is due to the fact that the storage

system heights are no longer limited by the reach height of the order picker. Shelves or storage

cabinets can be stacked as high as floor loading, weight capacity, throughput requirements, and/or

ceiling heights will permit. Man-aboard automated storage and retrieval systems are far and away the

most expensive picker-to-stock equipment alternative. Aisle-captive storage/retrieval machines reachingheights up to 40 feet cost around $125,000. Hence, there must be enough storage density and/or

productivity improvement over cart and tote picking to justify the investment. Also, because vertical

travel is slow compared to horizontal travel, typical picking rates in man-aboard operations range

between 40 and 250 lines per person-hour. The range is large because there is a wide variety of

operating schemes for man-aboard systems. Man-aboard systems are typically appropriate for slow-

moving items where space is fairly expensive.

[edit]Vertical lift module

The VLM is a board controlled automated vertical lift module. Inventory within the VLM is stored on front

and rear tray locations or rails. When a tray is requested, either by entering a tray number in the built in

control pad or by requesting a part through software, an extractor travels vertically between the two

columns of trays and pulls the requested tray from its location and brings it to an access point. The

operator then picks or replenishes stock and the tray is returned to its home upon confirmation.

VLM systems are sold in numerous configurations, which could be applied in different industries,

logistics, as well as office settings. The VLM systems could be customized to fully utilize the height of
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the facility, even through multiple floors. With the capability of multiple access openings on different

floors, the VLM system is able to provide an innovative storage and retrieval solution. The rapid

movement of the extractor as well as inventory management software can dramatically increase the

efficiency of the picking process. This occurs by simultaneously retrieving and storing trays in multiple

units. Unlike large AS/RS systems, which require a complete overhaul of the warehouse or production

line, the vertical lift modules are modularized, which can be easily integrated into the existing system, or

to be rolled out in gradually over different phases.

Most common applications include: MRO, order picking, consolidation, kitting, parts handling, buffering,

inventory storage, WIP, buffer storage, and many more.

VLMs provide floor space savings, increased labor productivity, improved worker ergonomics, and

controlled process.

Most VLMs offer dynamic space storage which measures the tray every time it's returned to the unit to

optimize space, safety features and some offer tilt tray delivery for increased ergonomic accessibility,

and laser pointers which indicate the exact item to be picked on each tray.

[edit]Horizontal carousels

A horizontal carousel is a series of bins which rotate on an oval track. Every bin has shelves which are

adjustable to .75" and can be configured for a myriad of standard and special applications. An operator

simply inputs a bin number, part number or cell location and the carousel will rotate via the shortest

path. Multiple horizontal carousels integrated with pick to light technology and inventory management

software (a pod of carousels) are used for order fulfillment.

A wave of orders are sent to the pod. A group of orders are selected to create a batch. The operator

simply follows the lights and pick round robin from the carousels and place items in a batch station

behind them. Each carousel pre-positions and rotates when picked. By applying the "product to picker"

principle, operators do not have to move from their position to prepare the order.

When the batch is complete, a new batch is inducted and the process repeated until the wave is

complete. Horizontal carousels can save up to 75% of floorspace, increase productivity by 2/3,

accuracy levels to 99.9%+ levels and throughput up to 750 lines per hour/operator.

Horizontal carousel systems generally outperform robotic systems for a fraction of the cost. Horizontal

carousels are the most cost effective AS/RS system available.[citation needed]

On a simplistic level, horizontal carousels are also often used as "rotating shelving." 'With simple "fetch"

command items are brought to the operator and otherwise wasted space is eliminated.

[edit]Installed applications
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Installed applications of this technology can be wide ranging. In some libraries, such as at UNR library,

such a system is employed to retrieve books. Still others in use involve retrieval of bicycles from

a bicycle tree, as in the case of systems in Japan.

nvolving the moving, handling, and storing of materials. Whether moving materialsmanually or mechanically, your employees should know and understand the potentialhazards associated with the task at hand and how to control their workplaces to minimizethe danger.

Because numerous injuries can result from improperly handling and storing materials,workers should also be aware of accidents that may result from the unsafe or improperhandling of equipment as well as from improper work practices. In addition, workers shouldbe able to recognize the methods for eliminatingor at least minimizingthe occurrenceof such accidents. Employers and employees should examine their workplaces to detectany unsafe or unhealthful conditions, practices, or equipment and take corrective action.

What are the potential hazards for workers?Workers frequently cite the weight and bulkiness of objects that they lift as majorcontributing factors to their injuries. In 1999, for example, more than 420,000 workplaceaccidents resulted in back injuries. Bending, followed by twisting and turning, were themore commonly cited movements that caused back injuries.

Other hazards include falling objects, improperly stacked materials, and various types ofequipment. You should make your employees aware of potential injuries that can occurwhen manually moving materials, including the following:

Strains and sprains from lifting loads improperly or from carrying loads that areeither too large or too heavy,

Fractures and bruises caused by being struck by materials or by being caught inpinch points, and

Cuts and bruises caused by falling materials that have been improperly stored or byincorrectly cutting ties or other securing devices.

What precautions should workers take when moving materials manually?When moving materials manually, workers should attach handles or holders to loads. Inaddition, workers should always wear appropriate personal protective equipment and useproper lifting techniques. To prevent injury from oversize loads, workers should seek helpin the following:

When a load is so bulky that employees cannot properly grasp or lift it,

When employees cannot see around or over a load, or

When employees cannot safely handle a load.

Using the following personal protective equipment prevents needless injuries whenmanually moving materials:

Hand and forearm protection, such as gloves, for loads with sharp or rough edges.

Eye protection.

Steel-toed safety shoes or boots.

Metal, fiber, or plastic metatarsal guards to protect the instep area from impact orcompression.
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See OSHA's booklet, Personal Protective Equipment(OSHA 3077), for additionalinformation.

Employees should use blocking materials to manage loads safely. Workers should also becautious when placing blocks under a raised load to ensure that the load is not releasedbefore removing their hands from under the load. Blocking materials and timbers shouldbe large and strong enough to support the load safely. In addition to materials with cracks,workers should not use materials with rounded corners, splintered pieces, or dry rot forblocking.

What precautions should workers take when moving materials mechanically?Using mechanical equipment to move and store materials increases the potential foremployee injuries. Workers must be aware of both manual handling safety concerns andsafe equipment operating techniques. Employees should avoid overloading equipmentwhen moving materials mechanically by letting the weight, size, and shape of the materialbeing moved dictate the type of equipment used. All materials-handling equipment hasrated capacities that determine the maximum weight the equipment can safely handle andthe conditions under which it can handle that weight. Employers must ensure that the

equipment-rated capacity is displayed on each piece of equipment and is not exceededexcept for load testing.

Although workers may be knowledgeable about powered equipment, they should takeprecautions when stacking and storing material. When picking up items with a poweredindustrial truck, workers must do the following:

Center the load on the forks as close to the mast as possible to minimize thepotential for the truck tipping or the load falling,

Avoid overloading a lift truck because it impairs control and causes tipping over,

Do not place extra weight on the rear of a counterbalanced forklift to allow anoverload,

Adjust the load to the lowest position when traveling,

Follow the truck manufacturer's operational requirements, and

Pile and cross-tier all stacked loads correctly when possible.

What precautions must workers take to avoid storage hazards?Stored materials must not create a hazard for employees. Employers should make workersaware of such factors as the materials' height and weight, how accessible the storedmaterials are to the user, and the condition of the containers where the materials arebeing stored when stacking and piling materials. To prevent creating hazards when storingmaterials, employers must do the following:

Keep storage areas free from accumulated materials that cause tripping, fires, or

explosions, or that may contribute to the harboring of rats and other pests; Place stored materials inside buildings that are under construction and at least 6

feet from hoist ways, or inside floor openings and at least 10 feet away fromexterior walls;

Separate noncompatible material; and

Equip employees who work on stored grain in silos, hoppers, or tanks, with lifelinesand safety belts.


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In addition, workers should consider placing bound material on racks, and secure it bystacking, blocking, or interlocking to prevent it from sliding, falling, or collapsing.

What safeguards must workers follow when stacking materials?Stacking materials can be dangerous if workers do not follow safety guidelines. Fallingmaterials and collapsing loads can crush or pin workers, causing injuries or death. To helpprevent injuries when stacking materials, workers must do the following:

Stack lumber no more than 16 feet high if it is handled manually, and no more than20 feet if using a forklift;

Remove all nails from used lumber before stacking;

Stack and level lumber on solidly supported bracing;

Ensure that stacks are stable and self-supporting;

Do not store pipes and bars in racks that face main aisles to avoid creating ahazard to passersby when r

SAFETY PRECAUTIONS

Wear safety shoes and helmets.2. Do not wear rings.3. Use

the accommodation ladder or brow for boarding or leaving

the ship.4. Use the ladders in the square of the hatch only

when the hoist is not in motion.5. Use the walkway on

the ships side away from the side on which cargois

being worked.6. Secure all lashings to permanent

deck fastenings. Never depend on movableobjects

lying on deck (dunnage, hatch covers, and so

forth).7. Secure hatch rollers properly.8. Lower blocks,

crowbars, slings, bridles, and other objects into the

hoIdby cargo falls or other lines. Do not drop or

throw.9. Stack hatch covers in an orderly manner.

Disorderly piles create trippingand stumbling hazards.10.

Lay strongbacks flat to prevent tipping over.11. When

removing or replacing strongbacks, keep them

between you andthe open hatch.12. Stand in theclear away from suspended loads.13. When steadying

loads, always face them and keep your feet in the clear.14.

Stand clear of slings being pulled from under

loads.15. Stand clear when strongbacks and hatch covers

are handled on the deck above.16. Be particularly careful

when handling objects with sharp or rough edges.17.

Learn and practice proper lifting techniques to


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prevent strains and sprains.18. Never walk

backwards.19. Step down from elevators, do not

jump.20. Report all defects in tools, materials, and

equipment.21. Report all injuries, however slight, and getimmediate first aid or medicalattention.22. Do not smoke

in holds and storerooms.23. Know the location of fire-

fighting equipment.24. Do not engage in

horseplay, practical jokes, or arguments while

workingcargo.


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ection One: Gravity ConveyorsSection Two: Powered Belt ConveyorsSection Three: Live Roller ConveyorsSection Four: Chain Conveyors

Section Five: SupportsSection Six: CouplingsSection Seven: AccessoriesSection Eight: Useful FormulasSection Nine: Essential Information Required

Section Ten: A Brief History of Conveyor

FORWARD

The package conveyor business has been in existence for almostone hundred years.Material handling engineering, in an over-simplified, basically,

consists of determining "how a product should be moved from oneplace to another, within the shortest allowable period of time, forthe least cost and with the least amount of manual effort".

We hope that this publication will help to guide you to the bestpossible solution to the many material handling problems, which

you may encounter.It is extremely difficult to put in to writing the many years of

problem solving experienced by "old-timers" in this industry, notwo solutions are identical. This publication will merely give you an

idea of the uses of the many different types of conveyors available,and, it will be up to you to sift through to determine the bestconveyor for your particular application.

SECTION ONE

GRAVITY

APPLICATION

Probably no other type of conveyor is applied to so many gravitymaterials handling uses as roller and wheel conveyor, handling

various packaged materials efficiently for distances as short as 2 ft.or as long as 100 ft. or more. Any item from light bulbs to bagged

cement to heavy castings can be moved on gravity.

Most items are best handled on roller conveyor, however, wheelconveyor may be substituted where a portable type gravityconveyor is required, where light weight containers (38 lbs. per ft.in steel, 18 lbs. per ft. in aluminum) are to be handled and wheresemi-rigid filled multi-wall paper bags or bales are to be handled.In general, roller conveyor should not be used for conveying burlapbags of coffee beans, paper or cotton bags of rice, cotton bags offlour or freshly filled paper bags of cement because the type ofmaterial mentioned has a tendency to drape over rollers.

Conveyors, when properly applied, confine the flow of materials
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A forklift truck (also called a lift truck, a fork truck, or a forklift) is a powered industrialtruckused to

lift and transportmaterials. The modern forklift was developed in the 1960s by various companies

including thetransmission manufacturing company Clarkand the hoist companyYale & Towne

Manufacturing.[1] The forklift has since become an indispensable piece of equipment in manufacturing

and warehousing operations.

Fork lift trucks

Hand pallet truck - no power system of any kind

Walkie low lift truck[5] - powered pallet truck, usually Electrically Powered[citation needed]

Rider low lift truck[5] - usually Electrically Powered
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Towing tractor[5]- Maybe Internal Combustion Engine or Electric Powered

Walkie stacker[5] - usually Electrically Powered

Rider stacker[5] - usually Electrically Powered

Reach truck [5]- Variant on a Rider Stacker forklift, designed for small aisles, usually Electrically

Powered, named because the forks can extend to reach the load. There are two variants, moving

carriage, which are common in North America, and moving mast which are common in the rest of

the world, and generally regarded as safer[citation needed]

Electric Counterbalanced truck[5]- comes in Stand on End Control, Stand on Center Control, and

Sit Down Center Control, which is the most numerous[citation needed]

Internal Combustion Engine Powered Counterbalanced Forklift[5]- comes in Stand on End

Control, Stand on Center Control, and Sit Down Center Control, which is the most numerous.

Engines may be diesel, kerosene, gasoline, natural gas, butane, or propane fueled, and may be

either Two Stroke Spark Ignition, Four Stroke Spark Ignition (common), Two Stroke Compression

Ignition, and Four Stroke Compression Ignition (common). North American Engines come with

advanced emission control systems. Forklifts built in countries like Iran or Russia will typically have

no emission control systems.[citation needed]

Electric Forklifts - Powered by lead-acid batteries, several types of forklifts are electric: cushion

tire forklifts, scissor lifts, order pickers, stackers, reach trucks and pallet jacks. Electric forklifts are

primarily used indoors on flat, even surfaces. Electric forklift batteries last 6 consecutive hours or

througho

A pallet jack, also known as a pallet truck, pump truck, orjiggeris a tool used to lift and

move pallets.

The front wheels are mounted inside the end of the forks, and as the hydraulicjackis raised, the forks

are separated vertically from the front wheels, forcing the load upward until it clears the floor. The pallet

is only lifted enough to clear the floor for subsequent tras

Safe workload of wire rea

WIRE ROPE SAFE WORKING LOADThe term safe working load

(SWL) of wire ropemeans the load that can be applied and still
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12/40

obtain themost efficient service and also prolong the life of

therope.The formula for computing the SWL of a wirerope is

the diameter of the rope squared, multiplied by8 (D x D x 8 = SWL

in tons).Example: The wire rope is 1/2 inch in diameter.Computethe SWL for the rope.The first step is to convert the 1/2 into

decimalnumber by dividing the bottom number of the fractioninto

the top number of the fraction: ( 1 divided by 2 = .5).Next,

compute the SWL formula: (.5 x .5 x 8 = 2 tons).The SWL of the

1/2-inch wire rope is 2 tons.NOTE: Do NOT downgrade the SWL

of wire ropedue to being old, worn, or in poor condition. Wire

ropein these conditions should be cut up an

Wire rope information page


13/40

1. Types of wire rope

The most common type of wire rope is called a galvanised steel 6/19 FC wire

rope - the 6 represents the number of outer strands each made up of thin wires- the 19 tells you the number of thin wires in each strand.

FC means 'fibre core' - in the early days this was a sisal string but in 2011 it is

a plastic string - often blue or green in colour.

2. Testing of wire ropes

This provides an interesting dilemma - if you fit eyelets to a length of wire

rope, then subject it to a tensometer test to confirm that this wire rope with

eyelets fitted is sufficiently strong, you are effectively damaging this wire rope

(by stretching) and it can no longer be described as 'new'.

For this reason, the Certificates of Compliance which we supply (if requested)

with every rope certify that the wire rope used conforms to international

standards and that the eyelets are fitted using equipment and techniques which

comply with international standards.

3. Breaking strength of wire ropes and Safe Working Load

There is a lot of information about this on the internet - the convention is to

'de-rate' the wire rope to 20% of its ultimate breaking strength. For example, a

galvanised steel 6mm diameter wire rope has a breaking strength of just over

2000kg - this translates to a 'Safe Working Limit (or Load)' of 400kg (= 20% of

2000kg).


14/40

The Safe Working Load (S.W.L.) and/or the year of manufacture is usually

stamped on the ferrules at one end of every rope, along with a unique rope

identification number.

More information can be found

here : http://www.engineeringtoolbox.com/wire-rope-strength-d_1518.html

4. Why not stainless steel wire ropes ?

Stainless steel wire ropes look great - shiny and 'new' for most of their life.

There lies the danger - stainless steel is prone to 'work hardening' and breaking

without warning. In many other applications the stainless steel rope does not

flex regularly and is therefore perfectly safe, but when used on crank-up towers

the wire ropes flex a lot when wound onto and off winch drums, around pulleysetc, making stainless steel an unsuitable material for the purpose.

There have been numerous documented cases recently of stainless steel wire

ropes on crank-up towers breaking without warning, often where an electric

winch system is used to frequently raise and lower the tower.

5. Installation

Follow the installation instructions carefully - wire ropes will quickly wear

and could break if they rub excessively against metal parts of the tower. For

example on Versatowers, the design is such that the wire ropes rub against

parts of the tower sections as they are raised or lowered - keep these areas well

greased.

In theory, different pulleys (sheaves) should be used for each different

diameter of wire rope 5mm, 6mm, 8mm etc - in practice most common pulleys

will be suitable for several different wire diameters.

6. Maintenance

Wire ropes should be kept well greased at all times. Use plenty grease and rub

it into the ropes. I have seen a set of wire ropes where a cheap grease had

actually caused the galvanised steel wires to rust rapidly (presumably this

grease contained some corrosive substance) - ordinary high-melting point

grease is suitable but beware of cheap varieties. Spray grease can be useful for

reaching inaccessible parts of the wire-rope after installation. Make sure

*every* part of the wire rope is greased.
http://www.engineeringtoolbox.com/wire-rope-strength-d_1518.htmlhttp://www.engineeringtoolbox.com/wire-rope-strength-d_1518.html


15/40

7. Inspection and replacement

A well-maintained set of wire ropes should last at least 5 years or more

(depending on correct installation, correct loading for the wire diameter,frequency of use, local weather conditions, etc) - the most common indicator of

when a wire rope needs replacement is when one or more of the thin outer

wires break - often these small sharp wire ends are difficult to see (especially

with a grease covering) so the only way to detect them may be to run your hand

along the rope and feel for them (caution - can/will be painful !)

Don't hesitate - if you feel even 1 small outer wire broken, the rope is

potentially dangerous and should be replaced immediately.

Another area where wire ropes fray and show signs of wear is just beside theeyelets/ferrules at the ends. Again look/feel for small broken wires.

________________________________________________

Wire rope information page

1. Types of wire rope

The most common type of wire rope is called a galvanised steel 6/19 FC wire

rope - the 6 represents the number of outer strands each made up of thin wires- the 19 tells you the number of thin wires in each strand.

FC means 'fibre core' - in the early days this was a sisal string but in 2011 it is

a plastic string - often blue or green in colour.

2. Testing of wire ropes


16/40

This provides an interesting dilemma - if you fit eyelets to a length of wire

rope, then subject it to a tensometer test to confirm that this wire rope with

eyelets fitted is sufficiently strong, you are effectively damaging this wire rope

(by stretching) and it can no longer be described as 'new'.

For this reason, the Certificates of Compliance which we supply (if requested)

with every rope certify that the wire rope used conforms to international

standards and that the eyelets are fitted using equipment and techniques which

comply with international standards.

3. Breaking strength of wire ropes and Safe Working Load

There is a lot of information about this on the internet - the convention is to

'de-rate' the wire rope to 20% of its ultimate breaking strength. For example, agalvanised steel 6mm diameter wire rope has a breaking strength of just over

2000kg - this translates to a 'Safe Working Limit (or Load)' of 400kg (= 20% of

2000kg).

The Safe Working Load (S.W.L.) and/or the year of manufacture is usually

stamped on the ferrules at one end of every rope, along with a unique rope

identification number.

More information can be found

here : http://www.engineeringtoolbox.com/wire-rope-strength-d_1518.html

4. Why not stainless steel wire ropes ?

Stainless steel wire ropes look great - shiny and 'new' for most of their life.

There lies the danger - stainless steel is prone to 'work hardening' and breaking

without warning. In many other applications the stainless steel rope does not

flex regularly and is therefore perfectly safe, but when used on crank-up towers

the wire ropes flex a lot when wound onto and off winch drums, around pulleys

etc, making stainless steel an unsuitable material for the purpose.

There have been numerous documented cases recently of stainless steel wire

ropes on crank-up towers breaking without warning, often where an electric

winch system is used to frequently raise and lower the tower.

5. Installation

Follow the installation instructions carefully - wire ropes will quickly wear

and could break if they rub excessively against metal parts of the tower. For
http://www.engineeringtoolbox.com/wire-rope-strength-d_1518.htmlhttp://www.engineeringtoolbox.com/wire-rope-strength-d_1518.html


17/40

example on Versatowers, the design is such that the wire ropes rub against

parts of the tower sections as they are raised or lowered - keep these areas well

greased.

In theory, different pulleys (sheaves) should be used for each different

diameter of wire rope 5mm, 6mm, 8mm etc - in practice most common pulleys

will be suitable for several different wire diameters.

6. Maintenance

Wire ropes should be kept well greased at all times. Use plenty grease and rub

it into the ropes. I have seen a set of wire ropes where a cheap grease had

actually caused the galvanised steel wires to rust rapidly (presumably this

grease contained some corrosive substance) - ordinary high-melting pointgrease is suitable but beware of cheap varieties. Spray grease can be useful for

reaching inaccessible parts of the wire-rope after installation. Make sure

*every* part of the wire rope is greased.

7. Inspection and replacement

A well-maintained set of wire ropes should last at least 5 years or more

(depending on correct installation, correct loading for the wire diameter,

frequency of use, local weather conditions, etc) - the most common indicator of

when a wire rope needs replacement is when one or more of the thin outerwires break - often these small sharp wire ends are difficult to see (especially

with a grease covering) so the only way to detect them may be to run your hand

along the rope and feel for them (caution - can/will be painful !)

Don't hesitate - if you feel even 1 small outer wire broken, the rope is

potentially dangerous and should be replaced immediately.

Another area where wire ropes fray and show signs of wear is just beside the

eyelets/ferrules at the ends. Again look/feel for small broken wires.

________________________________________________


18/40

Owing to the rapid growth of industries, complexities of fire riskhave increased enormously. Incidents of such fire risk have

increased enormously. Incidents of such fires not only result inhuge loss offire and property but also cause dislocation of work,loss of production, unemployment and so many other kinds of

suffering, If adequate fire prevention measures are taken thelosses can be minimized.

Dos Donts

1. Store flammable liquids gases, solvents, chemicalsin stable racks, correctly labeled.

2. Keep chemicals in cool and dry place away fromheat.

3. Where hazardous chemicals are used/stored,ensure adequate ventilation and prohibit smoking.

4. Maintain good house keeping. Ensure cigarettesare extinguished before disposal

5. Use fuses and circuit breakers of correct capacity.

6. Before welding operation, all traces of flammablematerial must be removed to a safe distance.

7. Welding/Hot work should be carried out underproper fire watch.

8. Keep all machinery clean and lubricate it to avoidfriction and overheating.

9. Regular fire drills should be carried out.

1. Dont smoke in prohibitedareas.

2. Dont place obstruction inmeans of escape.

3. Dont use damaged cords andavoid temporary connections.

4. Dont plug to many electricalappliances in one socket.

DOWNLOAD PRECAUTIONS FOR REFERENCE

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Last Updated : 06 May,2010

Fire is a Good Servant, But a Bad Master - Prevent Fire

IN CASE OF FIRE

Raise an alarm and inform the Fire Brigade on Telephone No. 101
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19/40

Attack the fire with available equipment, if you can do so without undue risk.

IF YOU HEAR THE FIRE ALARM

Leave the premises by the nearest available exit.

Close all doors and windows behind you.

Report to the person incharge at the assembly point.

IN THE INTEREST OF YOUR OWN SAFETY

You must know the escape routes, how to operate fire alarm and how to use firstaid fire fighting equipments.

Do not use lift as a means of escape.

Do not shout or run. This tends to cause panic.

Call the Fire Brigade

The services of the Fire Bridgade are provided free of cost Dial 101 irrespective ofthe size of the fire.

You do not need a coin to communicate on this number, even when you use theP.C.O.

HELP THE FIREMEN TO HELP YOU

Give way to fire engines to enable them to reach at the incident quickly. Allow them to use your telephone to communicate with the control room.

Dont park your cars/truck close to fire hydrants/underground static water tanks.

Guide firemen to water sources ie. Tube wells, pounds, static tanks etc. in case offire.

YOU SHOULD KNOW THAT

About 600 litres of water flow through a nozzle in a minute.

A water tender carries 4500 litres of water only.

If two nozzles are used to throw water on to the fire. It takes only 4 minutes toempty a water tender.

Hydraulic Platform/turn table ladders can reach to a height of 60m/45m undermost favourable operating conditions.

No objection certificate from Delhi Fire Service is not a guarantee against the outbreak of fire.

Availability of fire fighting equipment in the premises do not prevent out break offire. They help in minimizing the losses due to fire if maintained and operatedimmediately, effectively and efficiently.


20/40

Non-informing fire service about the fire incident is a cognizable offence.

Fire is a Good Servant, But a Bad Master - Prevent Fire

IN CASE OF FIRE

Raise an alarm and inform the Fire Brigade on Telephone No. 101

Attack the fire with available equipment, if you can do so without undue risk.

IF YOU HEAR THE FIRE ALARM

Leave the premises by the nearest available exit.

Close all doors and windows behind you.

Report to the person incharge at the assembly point.

IN THE INTEREST OF YOUR OWN SAFETY

You must know the escape routes, how to operate fire alarm and how to use firstaid fire fighting equipments.

Do not use lift as a means of escape.

Do not shout or run. This tends to cause panic.

Call the Fire Brigade

The services of the Fire Bridgade are provided free of cost Dial 101 irrespective ofthe size of the fire.

You do not need a coin to communicate on this number, even when you use theP.C.O.

HELP THE FIREMEN TO HELP YOU

Give way to fire engines to enable them to reach at the incident quickly.

Allow them to use your telephone to communicate with the control room.

Dont park your cars/truck close to fire hydrants/underground static water tanks.

Guide firemen to water sources ie. Tube wells, pounds, static tanks etc. in case offire.

YOU SHOULD KNOW THAT

About 600 litres of water flow through a nozzle in a minute.

A water tender carries 4500 litres of water only.


21/40

If two nozzles are used to throw water on to the fire. It takes only 4 minutes toempty a water tender.

Hydraulic Platform/turn table ladders can reach to a height of 60m/45m undermost favourable operating conditions.

No objection certificate from Delhi Fire Service is not a guarantee against the outbreak of fire.

Availability of fire fighting equipment in the premises do not prevent out break offire. They help in minimizing the losses due to fire if maintained and operatedimmediately, effectively and efficiently.

Non-informing fire service about the fire incident is a cognizable offence.


22/40

Fire Precautions in High Rise Buildings

The threat of fire in High Rise Buildings is constant and if adequate precautionary

measures are not taken, the consequences can be grave. Therefore, observe thefollowing basic precautions.

Dos

Good House Keeping must be ensured.

Always use ashtrays while smoking and deposit smoked butts in them after

extinguishing.

All receptacles for waste should be emptied at regular intervals.

Faculty electrical appliances should be repaired/replaced immediately.

Switches and fuses should conform to correct rating of circuit.

Welding /Cutting jobs should be carried out under strict supervision.

Keep smoke/Fire Check doors closed.

Keep means of escape clear of obstructions.

Fire Rescue drills should be carried out at regular intervals.

Impart elementary fire fighting training to occupants.

Emergency organization must be setup.

Donts

Dont dispose off lighted cigarette ends carelessly.

Dont plug too many electrical appliances in one socket.

Dont paint fire detector/sprinkler heads


23/40

Fire Precautions in Residential Area

Dos

Keep your house neat

and clean.

Keep matches, lighters

and crackers away from

children. Handle

crackers with care,

Use metal ashtrays while

smoking to dispose off

matches, used

cigarettes and bidis.

Papers, clothes andflammable liquids

should be kept away

from

heaters/stoves/open

choolahs.

Keep the escape

routes/staircases free

of any obstructions.

Use only one electrical

appliance in one

socket.

Keep LPG stoves on

raised platform Never

on the floor.

Turn off the cylinder

valve and burned knob

of the gas stove after

cooking.

Keep a bucket of water

handy while using

fireworks. In case ofBurn Injuries Due to

Fire, Pour Water Over

Burn Till Pain Subsides.

Donts

Dont middle with electrical fixtures like plugs,

wires switches and sockets.

Dont leave spray cans on or near heaters or in

direct sunlight they could explode.

Dont throw matches, cigarette ends or pipe

ash into waste pipe baskets.

Dont place oil laps, agarbattis or candles on

the floor or near combustible material.

Dont wear loose, flowing clothes while cooking

specially avoid synthetic clothing.

Dont keep crackers in you pocket or usefireworks inside the house.

Never light fireworks under confinement in a

metal container.

Never light flowerpot (anar) while holding it.

Never reach for any article over a fire.

Dont refill a burning stove. And never leave

open fire unattended.


24/40

Fire Safety PrecautionsAgainst Electricity


25/40

About 60% fires are of electric origin on account of electric short circuit,overheating, overloading, use or nonstandard appliances, illegal tapping ofelectrical wires, improper electrical wiring, carelessness and ignorance etc. Itcan lead to serious fire and fatal accidents, if proper instructions are notfollowed. Such incidents can be minimized to a great extent if adequate fire

precautions are observed. Electrical fires spread rapidly especially inbuildings and cause loss of lives and property. It is, therefore, necessary toact fast. Raise an alarm for help. Switch off power supply to de-energise theequipment. Use dry sand, CO2, dry powder or Halon extinguishers.

Dos

Use I.S.I. certified appliances.

Use good quality fuses of correct rating, miniature circuit breakers and earth leakage

circuit breakers.

Use one socket for one appliance.

Switch off the electric supply of the fire affected areas.

Fuses and switches should be mounted on metallic cubicles for greater safety against

fire.

Replace broken plugs and switches.

Keep the electrical wires away from hot and wet surface.

Switch off appliance after use and remove the plug from the socket. Switch off he

Main switch when leaving home for a long duration.Donts

Dont use substandard fixtures, appliances.

Never have temporary or naked joints on wiring.

Dont lay wires under carpets, mats or doorways. They get crushed, resulting in short

circuiting.

Dont lay wires under carpets, mats or doorways. They get crushed, resulting in short

circuiting.

Dont allow appliances cords to dangle.

Dont place bare wire ends in a socket.

Instruction for Fire Safety in Respect of Temporary Structures/Pandals

The height of the ceiling of the pandal should not be less than 3 metres.

No synthetic materials or synthetic ropes should be used in such structures.

Margins of at least 3 metres should be kept on all sides-away from any preexisting

walls or buildings.


26/40

No structure should be erected underneath any live electrical line.

Structure should be erected reasonably away from railway lines, electric substations,

furnaces or other hazardous places and a minimum distance of 15 metres should be

maintained.

Exits on all sides of the pandal shall be kept sufficiently wide (minimum 1.5

metres).There should be provision for stand by emergency light.

First-aid fire extinguishers or water buckets must be installed at strategic points

inside and outside of the pandal.

No combustible material like wood shavings, straw, flammable and explosive

chemicals and similar materials should be permitted to be stored in the vicinity or

inside the pandal.


27/40

No fireworks display with open flames of any kind should be permitted close to the

temporary structure/pandal. Kitchen must be segregated by providing separation

walls of noncombustible material (G.I. Sheets) from the remaining area of the

temporary structure.

The height of the ceiling of the pandal should not be less than 3 metres.

No synthetic materials or synthetic ropes should be used in such structures.

Margins of at least 3 metres should be kept on all sides-away from any preexisting

walls or buildings.

No structure should be erected underneath any live electrical line.

Structure should be erected reasonably away from railway lines, electric substations,

furnaces or other hazardous places and a minimum distance of 15 metres should be

maintained.

Exits on all sides of the pandal shall be kept sufficiently wide (minimum 1.5 metres).

There should be provision for stand by emergency light. First-aid fire extinguishers

or water buckets must be installed at strategic points inside and outside of the

pandal.

No combustible material like wood shavings, straw, flammable and explosive

chemicals and similar materials should be permitted to be stored in the vicinity or

inside the pandal.

No fireworks display with open flames of any kind should be permitted close to the

temporary structure/pandal.

Kitchen must be segregated by providing separation walls of noncombustible material

(G.I. Sheets) from the remaining area of the temporary structure

Fire safety during public/private functions

Frequent requests are received by Delhi Fire Service for providing fire safety for

providing fire safety cover in the public/private functions. The fire engines are

provided, subject to availability on payment of prescribed charges which at

present is Rs. 3000/ per day or part thereof. Rs. 200/ enhances these charges on

1st April every year as per the present policy.

The public should ensure that the auditorium/stadiums, which they are booking

for various functions are having valid No Objection certificate from fire

department. Therefore, such functions be held in those premises only, which arehaving clearance from fire service


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Fire Protections in Industries

Owing to the rapid growth of industries, complexities of fire risk have increased

enormously. Incidents of such fire risk have increased enormously. Incidents of

such fires not only result in huge loss of fire and property but also cause

dislocation of work, loss of production, unemployment and so many other kindsof suffering, If adequate fire prevention measures are taken the losses can be

minimized.

Dos

Store flammable liquids gases, solvents, chemicals in stable racks, correctly labeled.

Keep chemicals in cool and dry place away from heat.

Where hazardous chemicals are used/stored, ensure adequate ventilation and

prohibit smoking.

Maintain good house keeping. Ensure cigarettes are extinguished before disposal

Use fuses and circuit breakers of correct capacity.

Before welding operation, all traces of flammable material must be removed to a safe

distance.

Welding/Hot work should be carried out under proper fire watch.

Keep all machinery clean and lubricate it to avoid friction and overheating.

Regular fire drills should be carried out

Donts

Dont smoke in prohibited areas.

Dont place obstruction in means of escape.

Dont use damaged cords and avoid temporary connections.

Dont plug to many electrical appliances in one socket.

Basic Fire Precautions in Rural Areas

Every year thousands of fires occur in villages and farms resulting in heavy

losses and depletion of stock of the most valuable and vitally required

harvested crops meant for caving the teaming million from starvation. In many

cases, even lives are lost. Such incidents can be minimized if the following fine

precautions are observed.

Dos


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Extinguish cigarette/bidi ends and match sticks before disposal.

Keep combustible materials such as fuel wood, oil paints, spirits etc. in a separate

room.

The dwellings and huts should be constructed as far as possible with noncombustible

materials.

Electric installations should be carried out by a qualified electrician.

Burning of waste material, grass land, rubbish, stubble etc. should always be done

away from the residence under proper supervision.

Provide spark arrestors on Tractor Exhaust pipe.

While building up hay stacks, ensure that

o (i) A minimum distance of 20m from stack to stack or stack to residences is maintained

o (ii) Height of stack should not be more than 8m.

o (iii) Limit one stack to a maximum of 20 tonnes

o (iv) Keep water drums and few buckets near hay stacks.o (v) If possible, build up the stacks near tube wells, ponds, river or other water sources.

FACTORIES ACT

The object of the Factories Act is to regulate the conditions of work inmanufacturing establishments coming within the definition of the term "factory" as usedin the Act.

The first Act, in India, relating to the subject was passed in 1881. This wasfollowed by new Acts in 1891, 1911, 1922, 1934 and 1948. The Act of 1948 is more

comprehensive than the previous Acts. It contains detailed provisions regarding thehealth, safety and welfareof workers inside factories, the hours of work, the minimum age 6f, workers, leave withpay etc. The Act has been amended several times.

The Act is based on the .provisions of the Factories Act of GreatBritain passed in 1937.

In 1976 the Act was amended extensively. The provisions of the Amendment havebeen quoted and summarised at the appropriate .places in this chapter.

APPLICATION OF THE ACTThe Factories Act of 1948 came into force on 1st April 1949; It applies to

factories, as defined in. the Act, all over India, including the State of Jammu and

Kashmir.Unless 'otherwise provided, the Factories Act applies to factories belonging to the

Central or any State Government.--Sec. 116.

DEFINITIONS UNDER THE FACTORIES ACT.Factory. The term Factory is defined in Section 2 (m) of the Act as follows:

"Factory means any premises including the precincts thereof- .

(i). whereon ten or more workers are working, or were working on any day of


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the preceding twelve months, and inany part of which a manufacturing process is being carried on with the aidof power or is ordinarily socarried on, or

(ii) whereon twenty or more workers are working, or were working on any day of

the preceding twelve months, and in any part of which a manufacturing processis being carried on without the aid of power, or is ordinarily so carried on,___

but does not include a mine subject to the operation of the Indian Mines Act, 1952 (ActXXXV of 1952), or a mobile unit belonging to the armed forces of the Union, a railwayrunning shed or a hotel, restaurant or eating place.

Explanation.-Forcomputing the number of workers for the purposes of this clauseall the workers in different relays in a day shall. be taken into account.

[Clause 2(m) as amended in 1976.]Under Section 85, the State Government is empowered to declare any

establishment carrying on a manufacturing process to be a factory for the purposes ofthe Act even though it employs less than the prescribed minimum number of workers,

provided that the manufacturing process is not being carried on by the owner only withthe aid of his family.

Summary: From Sec. 2(m) of the Act it follows that m establishment comes withinthe definition of a Factory if the conditions stated below are satisfied :

1. It is a place where a "manufacturing process" is carried on.2. It employs the prescribed minimum number of "workers"

viz., ten if "'power" is used, and twenty if no "power" is used. It is sufficient if theprescribed number of workers were employed on any day of the preceding twelvemonths.3. . It is not a mine coming within the purview of the Indian Mines Act of 1952, arailway running shed, mobile unit belonging to the armed forces of the Union, a hotel,

restaurant or eating place.Manufacturing Process. This term is defined in Section 2(k) in a very wide sense.

It iIicludes :

(i) making, altering, ornamenting, finishing, packing, oiling, washing, cleaning,breaking up, demolishing, or otherwise treating or adopting any article orsubstance with a view to its use, sale, transport, delivery or disposal; or

(ii)pumping oil, water, sewage or any other substance; or (Hi) generating,transforming or transmitting power; or

(iii) (iv) composing types for printing, printing by letter press, lithography,photogravure or other similar processes or book binding ; or

(v) constructing, reconstructing, repairing, refitting, finishing or breaking up

ships or vessels ; or(vi) preserving or storing any article in cold storage.

For the corresponding section of the English Act, it was held that the differentprocesses enumerated in the clauses are merely illustrative so that laundries,,carpet beating, or bottle washing works come within the Act, if mechanical power isused. Patterson v. Hune

The following undertakings have been held to be manufacturing processes-bidi-making; conversion of raw-films into finished products; the preparation of


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eatables in the kitchen of a restaurant ; use of a refrigerator for adapting any articlewith a view to its sale.

The scraping out of salt and grading them, even though done by, manual labour,is a manufacturing process.

Worker. "Worker means a person employed, directly or by or through any

agency (including a contractor) with or without the knowledge of the principalemployer, whether for remuneration or not in any manufacturing process, or incleaning any part of the machinery or premises used for a manufacturing process,or in any other kind of work incidental to, or connected 'with, the manufacturingprocess" or the subject of the manufacturing process but does not include anymember of the armed forces of the Union."-Sec. 2(1), as amended in 1976.Explanation: Worker means any person engaged in any work connected with orincidental to a manufacturing .process. Thus the definition is wide. The term includespersons engaged directly and, also those who are engaged through an agency(including a contractor with or without the knowledge of the principal employer). Theterm includes clerical workers and persons paid by piece rates in a factory.

The term 'worker' does not include any member of the armed forces of Union. ., ,

, In case of a factory worker there must be a relationship betweenthe employer and the employed. "

Apprentices, whether remunerated or not, are workers within the meaning of theAct.Power. "Power means electrical energy, or any other form of energy which ismechanically transmitted and is not generated by human or animal agency."--Sec. 2(g).

Prime mover. "Prime mover means any engine, motor or other appliance whichgenerates or otherwise provides power."--Sec. 2(h).Transmission machinery. "Transmission machinery means any shaft, wheel, drumpulley, system of pulleys, coupling, clutch,'driving belt or other appliance or device by

which the motion of a prime mover is transmitted to or received by any machinery orappliance".--Sec. 2(i).Machinery. "Machinery includes prime movers, transmission machinery and all otherappliances whereby power is generated, transformed, transmitted or applied."--Sec. 2(j).Adult. "Adult means a person who has completed his eighteenth year of age".--Sec.2(a). Adolescent. "Adolescent means a person who ha$ completed his fifteenth year of agebut has not completed his eighteenth year."Sec. 2(b).Child. ''Child means a person who has net completed his fifteenth year of age." --Sec. 2( c) .

Young Person. "Young Person means a person who is either a child or an

adolescent."--Sec. 2(d).Calendar Year. "Calendar Year means the period of twelve months beginning with thefirst day of January in any year."

Sec. 2(dd). Day. "Day means a period of twenty four hours beginning at midnight." --Sec. 2 ( e) .References to the time of the day in the Act are to the Indian Standard Time. In areaswhere the I.S.T. is not observed, the State Government can by rules define the localmean time.--Sec. 3.


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Week. "Week means a period of seven days beginning 'at midnight on Saturday nightor such other night as may be approved in writing Jar a particular area by the ChiefInspector of Factories." --Sec. 2(f).Shift and Relay. Where work of the same kind is carried out by two or more sets ofworkers working during different periods of the day, each of such sets is called a "relay"and each of such periods is called a "shift."-Sec. 2(r).Occupier. "Occupier" of a factory means the person who has ultimate control over theaffairs of the factory, and where the said affairs are entrusted to a managing agent,such agent shall be deemed to be the occupier of the factory.--Sec. 2(n).

In case of a ship, which is being repaired or on maintenance work is being carriedout in dry dock which is available for hire, the following persons for certain section of the

Act will be deemed to be occupier (i) the owner of the dock, and (ii) the owner of theship or his agent or master or other officers-in-charge in the ship or any person whocontracts with such owner, agent or master or other officers-in-charge to carry out therepair or maintenance work.-Sec. 2(n) added by The Factories (Amendment) Act, 1976.

The Act imposes several duties and responsibilities on the occupier of thefactory. (See below).

An occupier of factory may be an owner, a lessee or a mere licensee but he musthave the right to occupy the property. He should also control the management.

APPROVAL, LICENCING AND REGISTRATION

It is necessary to obtain a" licence before a factory is started. Section 6 providesthat the State Government may make rules requiring, for the purposes of this Act, thesubmission of. plans or any class or description of factories to the Chief Inspector or theState Government, and the plans and specifications of a factory and its location.The Amendment of 1976 provides that any replacement and addition to the factory willnot be allowed if it does not reduce the I minimum clear space required for safe workingaround the plant or machinery or adversely affect the environmental conditions from theevolution or emission of steam, heat or dust or fumes injurious to health.

Notice by occupier. Section 7 provides that the occupier of a factory must, atleast 15 days before he begins to occupy or use any premises as a factory; send tothe Chief Inspector of Factories a written notice containing the following particulars:

( 1 ) the name and situation of factory ;

(2) the name and address of the occupier ; (3) the name and address of the owner of the premises or building (including theprecincts thereof) ;( 4) the address to which communications relating to factory may be sent ;(5) the nature of the manufacturing process to be carried on in the factory during thenext twelve months ;( 6) the total rated horse power installed or to be installed in the factory, which shall notinclude the rated horse power or any separate stand-by plant;(7) the name of the manager of the factory for the purposes of this Act ;(8) the number of workers likely to be employed in the factory ;(9) such other particulars as may be prescribed.

The rules stated above are enforced . because the plans and specifications of thefactory must insure proper measures of health, safety and welfare of the . workers.

THE INSPECTI0N STAFF


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The Factories Act empowers the State Government to appoint Inspectors, ChiefInspectors of Factories, Additional Chief Inspectors, Joint Chief Inspectors and DeputyChief Inspectors. Every DistrictMagistrate is an Inspector for his district. No person can act as an Inspector if .he is orbecomes directly or indirectly interested in a factory or in any process or businesscarried on therein or in any patent or machinery connected therewith. .

Powers of Inspectors. Section 9 provides that subject to any rules made in thisbehalf, an Inspector may exercise the following powers within the local limits for whichhe is appointed :(a) enter, with such assistants, being persons in the service of the Government or anylocal or other public authority, as

he thinks fit, and place which is used, or which he has reason to believe is used,as a. factory ;

(b) make examination of the premises, plant and machinery;(c) require the production of any prescribed register and any other document relating tothe factory, and take on the spot or otherwise statements of any person which he mayconsider necessary for carrying out the purposes of the Act; and .(d) exercise such

other powers as may be prescribed for carry ing out the purposes of this Act.No person shall be compelled under this section to answer any question or give

any evidence tending to incriminate himself.Under Section 91, an Inspector may take a sample of any subs tance, used or

intended to be used in a factory, for the purpose of finding out whether the substanceis injurious and if the factory is violating any of the provisions of the Act.Obstructing an Inspector. Whoever wilfully obstructs an Inspector in the exercise ofany power conferred on him by or under this Act, or fails to produce on demand by anInspector any registers Of other documents in his custody kept in pursuance of this Actor of any ru.!es made thereunder, or conceals or prevents any worker in a factory fromappearing before, or being examined by, an Inspector, shall be punishable ~withimprisonment for a term which may extend to three months or with fine which mayextend to Rs. 300 or with both.-Sec. 95. .

The onus is on the prosecution to show that a person has obstructed an inspector.

Duties of Inspector. It is the duty of factory inspectors to enforce the provisions ofthe Factories Act and other industrial laws. For this purpose they inspect factoriesperiodically. If any rule is violated they take steps like prosecuting the guilty persons etc.

CERTIFYING SURGEONS

Section 10 provides that the State Government may appoint qualified medicalpractitioners to .be certifying surgeons for the purposes of the Act for specified localareas or for specified factories or class of factories.

No person can be a certifying surgeon for a factory or industry in which he is

interested .directly or indirectly.-Sec. 10(3).The State Government may by order in writing and subject to specified conditions,exempt any person or class of persons from the provisions of this sub-section in respectof any factory or class or description of factories.

Duties. The certifying surgeon has the following duties under the Act and the rulesframed under it.

1. The examination and certification .of young persons.2. The examination of persons engaged in factories in dangerous


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occupations or processes. .3. Medical supervision of factories in cases where such supervision had been

prescribed owing to the dangerous nature of the work carried on or for any otherreason, viz.,(i) cases of illness have occurred which it is reasonable to believe are due to the natureof the manufacturing process carried on,. or other conditions of work prevailing therein;

(ii) by reason of any change in the manufacturing process carried on or in thesubstances used therein there is a likelihood of injury to the health of workersemployed in that manufacturing process ;

(iii) young persons are, or about to be employed in any work which is likely to causeinjury to their health.

(iv)

PROVISIONS REGARDING THE HEALTH OF WORKERS

Sections 11 to 20 of the Act contain certain provisions intended to ensure that theconditions under .which work is carried on in factories do not affect the health of theworkers injuriously. The summary of the provisions are explained below :

Summary of the provisions of the Factories Act. relating -to the health of workersare stated below.

1. Cleanliness. Every factory shall be kept clean and free from dirt, and the outflowof drains etc. The floors must be cleaned. Drainage shall be provided. Inside walls,partitions and ceilings must be repainted at least once in five years. When washablewater paint is used they must be painted once every three years and washed at leastevery period of six months.-Sec. 11,' as amended in 1976.2. Disposal of wastes and effluents. The waste materials produced from themanufacturing process must be effectively disposed off-Sec. 12.

3. Ventilation 'and Temperature. There must be provision for adequate ventilation bythe circulation of fresh air: The temperature

must be kept at a comfortable level. Hot parts of machines must be'separated and insulated.-Sec. 13.

4. Dust and Fume. If the .manufacturing process used. gives off injurious or offensivedust and fume steps must be taken so that they are not inhaled or accumulated. Theexhaust fumes of internal combustion engines must be conducted outside thefactory.--Sec. 14.

5. Artificial humidification. The water used for this purpose must be pure. It must be.taken from some source of drinking water supply. The State Government can framerules .regarding the process of humidification etc.-8ec. 15. .6. OverCrowding. There must be no overcrowding in a factory. In factories existingbefore the commencement of the Act there must be at least 350 c.ft. (~r 55 cubic

metres) of space per worker. For factories built afterwards, there must be at least 500c.ft. (or 75 cubic metres) of space. In calculating the space, an account is to be takenof space above 14 ft. (or 5 metres) from the floor.-Sec. 16.7. Lighting. Factories must be well lighted. Effective measures must be adopted toprevent glare or formation of shadows which might cause eyestrain.-sec. 17.8. Drinking water. Arrangements must be made to provide a sufficient supply ofwholesome drinking water. All supply' points of such water must be marked "drinkingwater". No such points shall be within 20 ft. (or 7.5 metres) of any latrine, washing place


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etc. Factories employing more than 250 workers must cool the water during the hotweather.-Sec. 18. .

9. Latrines and Urinals. Every factory must provide' sufficient number of latrines andurinals. There must be separate provision for male and female workers. Latrine andurinals must be kept in a clean and sanitary condition. In factories. employing more

than 250 workers, they shall be of prescribed sanitary types.--sec. 19.PROVISIONS REGARDING THE SAFETY OF WORKERS

Sections 21 to 40A, 40B and 41 of the Act lay down rules for the purpose ofsecuring the safety of workers. Summary of the provisions of the Factories Actregarding the safety of the workers are stated below: (Sections 2l to 41) .

1. Fencing ot machinery.All dangerous machinerymust be securely fenced e.g.,moving .parts- of prime movers and flywheels connected to every prime mover. electricgenerators. etc.-Sec. 2l.

2. Work on or near machinery in motion. Work on or near machinery in motionmust be carried out only by specially trained adult male workers wearing tightly fittingc1othes.-Sec. 22.

3. Employment of young persons on dangerous machines. No young personshall work at any danger()us machine' unless he has been specially instructed as tothe dangers and theprecautions to be observed. has received sufficient training aboutth~ work. and is under the supervision of some person having thorough knowledge andexperience of the machine.-Sec. 23.

4. Striking gear and devices for cutting off power. In every factory suitabledevices forcutting off powerin emergencies from running machinery shall be providedand maintained in every workroom.~. 24.

5. Self-acting machines. Moving parts of a self-acting machine must not be

allowed to come within 45 cms. of any fixed structure which is not part of the machine.-Sec. 25.6. Casing of new machinery. In all machinery installed after the commencement

of the Act. certain parts must be sunk, encased or otherwise effectively guarded e.g..set screw. bolt. toothed gearing etc. -sec. 26.

7. Women and children near cotton Openers. Women and children must not beallowed to work nearcot/On openers, except In certain cases.-Sec. 278. Hoists, lifts, chains etc, Every hoist and lift must be so constructed as to be safe.There are detailed rules as to how such safety is to be secured. There are similarprovisions regarding lifting machines. chains, ropes and lifting tackle .Sec. 28. 29.

9. .Revolving machinery. Where grinding is . carried on the maximum safe

working speed of every revolving machinery connected therewith must be notified.Steps must be taken to see that the safe speed is not exceeded.-Sec. 30.

10. Pressure plant.Where any operation is carried on at a pressure higher thanthe atmospheric pressure, steps must be taken to ensure that the safe workingpressure is not exceed~cL-.sec. 31.. 11. Floors, stairs and means of access.All floors, steps, stairs, passage andgangways shall be ofsound construction and properlymaintained. Handrails shall be


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provided where necessary. Safe means of access shall be provided to the place wherethe worker will carry on any work.-Sec. 32.

12. Pits, sumps. openings in floors etc. Pits. sumps. openings in floors etc.must be securely coveredor fenced.-Sec. 33.

13. Excessive weights. No worker shall be made to carry a load so heavyas to

cause him injury.-8ec. 34.14. Protection ofeyes. Effective screen or suitable goggles shall be provided toprotect the eyes of the worker from fragments thrown off in course of any manufacturingprocess and from excessive light if any.-Sec. 35.

15. Precautions against dangerous fumes. No person shall be allowed to enterany chamber. tank etc. where dangerous fumes are likely to ,be present. unless it isequipped with a manhole or other means of going out. In such space no portableelectric light of more than 24 ,volts shall be used. Only a lamp or light of flame proofconstruction can be used in such space. For people entering such space suitablebreathing apparatus, reviving apparatus etc. shall be provided. Such places shall becooled by ventilation before any person is allowed to enter.-8ecs. 36 and 36A.

16. Explosive or inflammable gas etc. where a manufacturing processproduces inflammable gas. dust. fume. etc. steps must be taken to enclose themachine concerned, prevent the accumulation of substances and exclude all possiblesources of ignition. Ext

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