Professional Documents
Culture Documents
Larsen & Toubro Limited: E & C Division
Larsen & Toubro Limited: E & C Division
E & C Division
Safety Health & Environment Manual
for
Construction Site
E & C Division
SHE Manual
Contents
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.
3.2.3.3.
3.2.3.4.
Site Engineer
3.2.3.5.
3.2.4. Returns
3.2.4.1.
3.2.4.2.
Monthly Reports
3.2.4.2.1. Monthly statistics report
Format
Format
E & C Division
SHE Manual
SHE Training
3.9.1. Tool Box Talks
3.9.2. Training at Site
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
E & C Division
SHE Manual
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
7.4.1
7.4.2
Wire Ropes
7.4.3
7.5
Hoists
7.6
8. Critical Jobs:
8.1
8.2
Confined Space
10.1.2
Lighting
10.1.3
Contents
E & C Division
11
12
Electrical Safety
13
SHE Manual
13.1 Radiography
14
15
16.2.
17.
Fire prevention
18.
Contents
FOREWORD
J.B.Desai
Dy.General Manager
Safety Control. E & C Div.
E & C Division
SHE Manual
1. Introduction
1.1.1
1.1.2
1.1.3
Introduction
To Engineer and Execute projects with consistent quality, cost and delivery in line with
the requirements of our customers, and to exceed or meet their expectations, whilst
enhancing 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 all
applicable statutory and regulatory requirements.
4.
To advance / ensure the use of better and cleaner technology to minimise adverse
environmental impacts.
5.
6.
7.
To comply with all applicable occupational Health & Safety legislation and continually
improve safe working practices through setting health and safety objectives and
ensure good health, safety and security of all our people, our biggest asset.
8.
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 our
Nation.
10.
As an undisputed leader in the Indian context, we continue to make things that make
India proud, and shall strive to be amongst the globally outstanding companies, which
the World is proud of.
__________________________
K. VENKATARAMANAN
(Member of the Board & Sr. VP)
E & C Division
3.
SHE Manual
3.1.
Management Commitment
The E&C Division of L&T, is committed to continuous
improvement 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.
SAFETY COMMITMENT
Pursuant to the L&T Safety Policy Statement, we L&T employees at this
site shall comply with the L&T Safety Management System by the
following actions.
!
!
!
!
!
!
!
!
!
SAFETY FIRST
E & C Division
3.2.
SHE Manual
SHE Structure
The SHE organisational structure of L&Ts E & C Division Safety
Managements system and personnel responsible for safety
aspects are as follows:
Chief
(Management
Services)
Cluster Heads
Business
Group Leaders
Head
(Project Management/ER&C)
Head
(Safety)
Resident
Construction Managers
Site Safety
Officers
Safety
Engineers
LEGEND
: Communication / Interaction
E & C Division
3.2.1.
SHE Manual
Head
(Safety)
Safety
Engineers
3.2.2.
Site Safety
Officers
3.2.3
3.2.3.1.
Management
3.2.3.1.1
E & C Division
3.2.3.2.
SHE Manual
E & C Division
SHE Manual
Site Engineer
The site engineer is responsible for ensuring the compliance
of the statues and the recommendations given in this manual
by the contractor and sub-contractors working under them. In
addition to this he will:
Investigate near miss incident and accident reports and monitor the
site safety performance against L & Ts internal standards.
E & C Division
SHE Manual
E & C Division
3.2.4.
SHE Manual
Returns
Objective
In order to conform with norms set in the safety policy, it is
essential to know in advance the opening and closing of a
site.
A detailed procedure is given below for compliance.
3.2.4.1.2.
3.2.4.1.2.1
3.2.4.1.2.2
3.2.4.1.2.3
3.2.4.1.2.4
3.2.4.1.2.5
3.2.4.1.3.
3.2.4.1.3.1.
Procedure
This Procedure requires that SCD at Powai should be
informed about opening and closing of a construction site
within seven days of its opening/ closing.
The information to be sent to SCD, Powai shall be filled in
the format annexed to this Procedure.
It should be sent by a fax message (No. 022 - 8581020) for
the attention of Head-Safety Control followed by a
confirmatory copy by post/ courier.
Project Execution Manager at Powai / Baroda shall be
responsible to provide the information. However, RCM/ RCE
shall ensure that the information has been sent to SCD,
upon taking charge of the site.
All construction sites of E & C Division shall be covered
under this Procedure so long as any person/s of E & C
division and/ or its appointed contractors/ agents carry out
activity of any kind at the site.
Definitions
Opening of a Construction Site
E & C Division
3.2.4.1.3.2.1.
3.2.4.1.3.2.2.
3.2.4.1.4.
SHE Manual
3.2.4.1.5
RECORD
Forms
Site opening and closing Report
Records
CSC 10 R2
E & C Division
SHE Manual
Annexure -1
Safety Control
E & C Division
(A)
SITE
OPENING
REPORT :
2.
3.
4.
Complete address
6.
Telephone,
V-sat (hotline) & fax
nos.
e - mail address
Name of Resident Construction
Manager / Resident Engineer
Names of Site Engineers
7.
8.
9.
Estimated no. of
10.
11.
14.
15.
5.
12.
13.
Date: __________
man-hours
Available at site /
required at site
Signature: ________________________________
Name
: ________________________________
10
E & C Division
SHE Manual
Annexure 2
Larsen & Toubro Limited
Powai, Mumbai
Safety Control
E & C Division
SITE CLOSING
REPORT :
Date: __________
Signature
: _____________________
Name
: _____________________
(Project Execution Manager/
Resident Construction Manager)
Copies to:
: All SBU Heads
: Project Execution Manager - Powai/ Baroda
: Champion of concerned SBU
11
E & C Division
SHE Manual
3.2.4.2.
3.2.4.2.1.
Objective
3.2.4.2.1.1.
3.2.4.2.1.2.
3.2.4.2.2.
Procedure
3.2.4.2.2.1.
SSO shall write the correct Accident Data & Man Hours as
per the standard format given by Safety Control Dept. E &
C Division.
SSO & RCM shall sign report. If RCM is not present, his
representative will have to sign and to be forwarded to
Safety Control Dept. in the first week of every month.
Monthly statistic report are processed and analysed by
Safety Control Dept. and performance is evaluated for
further action. Also it will be published in quarterly safety
bulletin.
3.2.4.2.2.2.
3.2.4.2.2.3.
3.2.4.2.3
Administration
3.2.4.2.3.1
3.2.4.2.3.2
3.2.4.2.3.3
3.2.4.2.4
Clarification
3.2.4.2.4.1
12
E & C Division
3.2.4.2.4.2
3.2.4.2.4.3
3.2.4.2.5
SHE Manual
Form
3.2.4.2.5.1 Monthly Statistic Report
Reference
CSC-02-R1
13
Annexure
Date of Issue
: __________________
Project Name & Job No. : __________________
Ref.: CSC-02-MR-R1
Accident Data
No. Of
incidents
Person
Involved
No. of
Contractors
involved
lost
No. of
person
injured
No.
of
equipment
damaged
Loss
in
Rs.
No. of
First aid
cases
No. of
person
injured
No. of eqpt.
Damaged
Man
hours
No. of
people
lost
L&T
If any
No. of
reporting
to Govt.
Minor Injuries
For the month under report ( ____2000)
Cumulative
From _______ 1999 to________ 2000
No. Of Man
cidents
hours
Fires
No. of
fires
reporting
outside
No. of
NearMiss
Details
L&T E & C
(A)
Main Contractors
(B)
Sub-contractors
(C)
No. of People
__________________
Signature of RCM
Date :
Copy distribution :
E & C Division
SHE Manual
3.2.5.
3.2.5.1.
Objective
Procedure Nos. CSC-01 and CSC-02 deal with reporting of
accidents and mishaps at E & C Division construction sites.
These reports give negative information, albeit necessary,
about Safety Performance & Management at the sites and
enables measurement of safety in terms of reduction in
injury/harm/loss.
However, when Safety Performance is good, and injury & loss
are low at a particular site, these negative measurements are
not sufficient to have adequate feedback for managing safety,
because potential for injury/mishap may be high at the site
but likelihood of risk of events may be very low. Hence,
absence of accidents is not a sufficient indication of good
Safety Management and other measurements of Safety
Performance are necessary to have assurance that the
absence of accidents is due to good Safety Management.
3.2.5.2.
Procedure
The Procedure deals with formally reporting to the Safety
Control Department (SCD) of E & C Division, at Powai, in
writing, about the positive aspects of safety such as follows in
construction activities at sites.
(a) Compliance to Safety Control Procedures (CSC) in the
Procedure Manual.
(b) Provision and use of APTs to/by L&T and Contractors at
site
(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 display
etc.
(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 manhours.
14
E & C Division
SHE Manual
Administration
(a) Whenever a positive action is taken at the site, RCM/E
will send its details to SCD in the form attached to this
Procedure. Both RCM/E and SSO will sign the form.
(b) The information may be sent at any time, as and when
the positive safety action is taken at the site.
(c) Safety Officer from SCD will check the actual provision of
the measure/s reported by RCM/E, when he visit the site.
(d) SCD will record the action and use it for co-relation of
such actions with the Safety Performance of the site and
also use it for safety awards, when instituted in E & C
Division.
15
E & C Division
SHE Manual
Annexure
Positive Safety Measure/Action
Name of Site
Ref.
Date
:
:
:
Date of action/
implementation
Description
Whether one-time or
Continuous/regular
(Frequency)?
We shall ensure that this measure/practice will continue until the site is
closed.
_____________________
Site Safety Officer
Name:
__________________________
Resident Construction
manager / engineer
Name:
16
E & C Division
3.2.6.
SHE Manual
17
E & C Division
SHE Manual
Annexure
DATE
SR.
NO
OBSERVATIONS
ACTION TAKEN
SIGN OF SSO
SIGN OF RCM
18
E & C Division
SHE Manual
3.2.7.
3.2.7.1.
3.2.7.1.1. Objective
One of the Codes of Conduct in the E & C Division - Safety
Policy Statement is to promote interest and enthusiasm in
safety efforts through awareness and recognition of safety
performance. This is possible, if all persons working at the
L&T site are informed about the safety performance at the
site. Efforts to correct/improve poor safety performance and
to maintain good safety performance will be put by people at
the site, if they know about the current performance, on
continuous basis.
One of the methods of informing persons working at the site
about safety performance of the site, is by displaying it on a
board which is placed prominently and up-dated daily.
Persons working at the site, when they read the information
on the Board, will feel proud of their good safety performance
and will strive to maintain it.
The objective of this Procedure is to require all
construction sites to display information about the
safety performance of their individual sites.
3.2.7.1.2. Procedure
The Procedure deals with the preparation, installation and
updating of the Display-Board giving up-do-date, correct and
accurate information about safety performance of the
construction site, where the Board is installed.
19
E & C Division
SHE Manual
1500 mm L x 1000 mm H
(Dimensions may be reduced
proportion-ately to suit site
conditions but not below 1000
mm L x 800 mm H).
Material
Colour
Background
: White
Lettering
: Dark Green
Numbers & L&T Logo: Black
Layout
Quantity
English or Hindi
Local language
20
E & C Division
SHE Manual
3.2.7.1.6. Administration
(a) Within 15 days from the effective date of this Procedure
RCM/Site In-charge will get the Display Board/s ready
and have them installed at any of the suggested
locations mentioned in 2.2 above.
(b) Nos. of days to be displayed will be from the date of the
last LTA/MI/DI. (See Definitions in 3.8).
(c) The
safety
performance
shall
cover
persons/equipment/assets of L&T-Group II (P) and of all
its Contractors at the site.
(d) Responsibility of operating/updating the Board shall be of
the Site Safety Officer (SSO). If SSO is not present at
the site, then RCM or his designated person shall be
responsible for operation/updating of the Board.
(e) Name of the person responsible for operation of the
Board and date of updating shall be clearly shown on the
Board.
(f) SSO/RCM shall update the information on the Board
every day (except on weekly offs) at 9 A.M., after
reviewing information of the previous 24 hours.
(g) Safety Officer from SCD (Powai) shall include, in his
inspection, working of this Procedure, during his site
inspection/audit and check that the information matches
with the one provided through Accident Reports sent to
SCD 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 below
for ready reference.
Lost Time Accident (LTA):
An incident which causes death of a person or which causes
bodily injury to a person due to which s/he is prevented from
working for a period of 48 hours
or more immediately
following the incident.
Minor Injury (MI) :
An incident which causes bodily injury/ies to a person, who is
treated by the first-aid facility at the site or by a doctor and
who is permitted to work at the site, immediately after the
first-aid treatment.
SHE Organisation & Management
21
E & C Division
SHE Manual
22
DATE
PEOPLE ON THIS
L & T E & C DIVISION SITE
HAVE WORKED
D
A
Y
S
D
A
Y
S
400
WITHOUT DANGEROUS
INCIDENT FOR
D
A
Y
S
200
400
JixBE +{vi BE x
S] BE x
n
x
230
n
x
350
cxBEBE nv]x BE x
500
1500
n
x
500
Annexure
1200
WITHOUT MINOR
INJURY FOR
SITE NAME
JOB NO.
E & C Division
3.3.
SHE Manual
Statutory Requirements:
The Government of India has enacted THE BUILDING AND
OTHER CONSTRUCTION WORKERS (REGULATION OF
EMPLOYMENT AND CONDITIONS OF SERVICE) ACT, 1996
AND THE BUILDING AND OTHER CONSTRUCTION
WORKERS
(REGULATION
OF
EMPLOYMENT
AND
CONDITIONS OF SERVICE) CENTRAL RULES 1998 and the
copy 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.
24
E & C Division
SHE Manual
3.4.
(A)
Objective
This procedure is to scrutinise / evaluate L & T Construction
Contractors w.r.t their sutability to work safely on L & T sites.
It is expected that by emloying the contractors who meet the
qualification requirements laid in this procedure, accidents and
dangerous occurences on L & T sites would be minimised. By
following the procedure, L & T Manager should encourage
contractors on safety and make every effort to qualify them by
advising them corrective actions to be taken by them.
(B)
PROCEDURE
The Procedure covers basically four situations / status w.r.t. the
contractors at E & C Division sites and these are shown in tables
below :
CONTRACTOR
STATUS
1. New
(Not qualified in
safety by L & T)
2. New
(Not qualified in
safety by L & T)
3. Existing
(Not qualified in
safety by L & T)
4. Existing
(Not qualified in
safety by L & T)
CONTRACTOR
ACTIVITY
PROCDURE
NO. CSC-03/
/1
/2
/3
/4
25
E & C Division
3.
4.
5.
6.
SHE Manual
In any case, the original must come to Head Safety Control and
others retain copies.
Safety Control Engineer (SCE) from Safety Control scrutinises the
information and visits the contractor office / sites for inspection, if he
finds more than 80 % of the requirements are met . SCE advises the
contractor about the shortfalls, if any.
If 80 % requirements not met, Head Safety Control reject the
contractor s application to register and asks him to resubmit when is
ready to meet the requirements. If the contractor intends to know,
Head Safety Control will inform the contractor in writing about his
shortcomings in safety qualification.
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 BUHs / DGMs / AGMs / PMs
/ SMs by a memo and a copy of updated list of prequalified
contractors.
If during the site inspection of SCE , any shortfall in the qualified
contractor safety capability is observed , he will be instructed to
corect 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 BUHs / DGMs / AGMs /
PMs / SMs by a memo and a copy of updated list of prequalified
contractors. Name of the disqualified conractor will be deleted in
this list.
It will be decision & responsibility of PM / SM about the continuation
of services of the subject contractor at the ongoing sites. In any
case, the contractor shall not be awarded any new contract for
work/services, untill he requalifies in safety.
2.
Project / Site Manager will send the CSCE form along with other
documents of RFQ , to all prospective contractors, who are not
qualified in Safety with L & T E & C Division.
When PM / SM receives the filled - in CSCE , he will send original to
DGM ( QA & I ), retaining a copy of the same.
26
E & C Division
3.
4.
5.
6.
7.
SHE Manual
27
E & C Division
(C)
SHE Manual
Administration
(a) Books containing 5 sets of CSCE Forms will be sent to all sites
by Safety Control Department . More forms can be obtained
from Safety Control Department. However, if forms are
exhausted, the CSCE should be prepared in photocopy/typed
copy and submitted to Head Safety Control.
(b) SE will periodically check at all E & C Division Sites whether the
contractors working at sites are qualified in Safety by L & T
and advise Sr. V. P. / BUH s about the status every quarter.
(D)
-
Definitions / Abbreviations
28
E & C Division
SHE Manual
Objective
Procedure No. CSC-06 stipulates that the standard Terms &
Conditions (T&C) of HSE should be included in the
contract/purchase orders issued to the L&T site contractors, by the
respective 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 made
aware of these T&C, it is necessary that these T&C are available
readily 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 to
all L&T-and contractors-managers, engineers, supervisors and
safety officers, who are concerned with health and safety of their
employees working at the site.
The following actions are required to be taken by RCM/RCE of
L&T/LTCG (in case of site synergy situation).
1.
2.
3.
4.
5.
29
E & C Division
(C)
SHE Manual
Administration
1.
2.
3.
4.
5.
30
To enable us to assess & evaluate you capabilities in Safety please complete & return to:
LARSEN & TOUBRO LIMITED
TELEPHONE : 022-8581401/1411
E & C Division Safety Control Department
TELEFAX
: 022-8581020
Saki Vihar Road, P.O.Box 8901, Powai, Mumbai 400 072, India
TO BE UPDATED IN
JANUARY EVERY YEAR
COMPANY NAME
TELEPHONE NUMBER
FAX NUMBER
PRIVATE
GOVERNMENT
PARTNERSHIP
PROPRIETRY
CONTRACTORS
OTHERS (SPECIFY)
MECH.ERECTION
PIPING
ELECTRICAL
INSULATION
PAINTING
STRUCTURAL
OTHERS (SPECIFY)
INSTRUMENTATION
SCOPE OF APPROVAL
THE SCOPE OF APPROVAL DETERMINES THE NATURE OF YOUR SERVICES YOU INTEND TO PROVIDE TO L&T
Yes / No
No.
No. of job-sites
Involved
No. of man-hours
worked
Compensation paid /
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
No. of persons
Involved
______
_______________
________________
___________________
______
_______________
________________
___________________
______
_______________
________________
___________________
______
_______________
________________
___________________
______
_______________
________________
___________________
______
_______________
________________
___________________
______
_______________
________________
___________________
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 INFORMATION
1. Give additional information (on safety), if any.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
SECTION F YOUR PROPOSAL FOR THE SPECIFIC JOB-SITE FOR WHICH ARE BIDDING TO L&T
1. 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 & its
surroundings? Give details.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
E & C Division
3.5
SHE Manual
Safety Committee
3.5.1. Introduction:
Statutorily (See section 38 of The Building and other construction
workers (Regulation of employment and condition of service) Act
1996) each site should have a safety committee having equaled
number of representatives from management and workers/
contractors. A well-planned safety committee is a great motivator
for safety. Its primary purpose is to enable management and
workers to work together to monitor the site safety plan, so as to
prevent accidents and improve working conditions on site. Its
size and membership will depend on the size and nature of the
site and upon differing legal and social conditions in the state
concerned, but it should always be an action orientated group of
people in which both management and workers are represented.
The safety committee carrying out a site inspection together
raises the level of safety consciousness at the site.
The procedure for forming the safety committee, scope and
objectives of the committee, meeting procedures, minutes
preparation and circulation and follow up action is listed in
annexure.
31
E & C Division
SHE Manual
Annexure
2)
Meeting Frequency
a.
b.
3)
4)
Administration
a.
32
E & C Division
SHE Manual
33
E & C Division
SHE Manual
Site _______________
Date of Issue ________
Sheet ____of ____
Name
Company
Signature
34
E & C Division
SHE Manual
Site:________________
Date of Issue: _______
Sheet ____of ____
E & C Division
Action
By
Target
Date
for
action
Actual
CompleTion
Date of
Action
___________________________
____________________
Note:
1. Report should be legible, properly typed.
35
E & C Division
3.6
(A)
Objective
(i)
(ii)
(iii)
(iv)
(v)
(B)
SHE Manual
Procedure
The procedure deals with making available General Construction
Safety Plan (CSP-G) to Marketing, Prospective Clients (through
Marketing), Project Execution and Construction Departments of E &
C Division, who have all to play important roles in its
implementation in the steps described below.
36
E & C Division
(C)
SHE Manual
2.
3.
Event
Action
Action
By
Marketing
Marketing
Marketing
Marketing
SCD
Marketing
Marketing
37
E & C Division
Step
No.
4.
SHE Manual
Event
Techno-Commercial
discussions with the
client
Action
Action
By
Marketing
+
Project
Execution
Marketing
+
Project
Execution
5.
Contract/Purchase Order
with the client
Marketing
6.
Project Execution
Marketing
7.
15 days before
Construction starts
8.
Project
Execution
SCD
Resident
Manager
38
E & C Division
SHE Manual
Administration
(i)
(ii)
(iii)
(iv)
(E)
Definitions
(i)
(ii)
(iii)
(iv)
39
E & C Division
3.7
(A)
Objective
(i)
(ii)
(iii)
(B)
SHE Manual
Definitions
Fatal : Death resulting from an accident.
LTA (Lost Time Accident):
An injury causing disablement of an injured person beyond 48
hours 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 part
there of.
(b) Crushed or serious injury to any part of the body due to which
loss 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 greater
than atmospheric pressure.
(b) Collapse or failures of any lifting machine (crane, wire rope
hoist, chain pulley block, etc), lifting Tackle (chain sling, wire
rope sling, shackle, clamp, etc.) and lifts (passenger, goods
and service).
(c) Explosion, fire, bursting out, leakage or escape of any molten
metal, hot liquor or gas, which results into injury or material
damage.
40
E & C Division
SHE Manual
Procedure
The procedure deals with reporting of accidents involving people,
machinery, buildings, structure, surroundings, environment (air,
water, land), dangerous occurrence and near accident & first aid
occurrence which could have resulted in an accident and / or
dangerous situation.
1.
2.
3.
4.
41
E & C Division
(i)
SHE Manual
(ii)
42
E & C Division
SHE Manual
(D)
Administration
1.
2.
43
E & C Division
3.
(E)
SHE Manual
Records
1.
2.
3.
4.
Form
Accident Report
Accident Investigation
Near miss Accident Report
First Aid Accident Report
Reference
CSC-01-R1-AR.
CSC-01-R1-AI.
CSC-01-R1-NA.
CSC-01-R0-FAAR.
44
ACCIDENT REPORT
(CSC-01-R1-AR NO.__________)
SBU
! Fire / Explosion
! Mechanical
! Collapse of Structure
! Others ( Specify ) :
! Injury
! Property damage
! Material loss
! Environment pollution
! Others ( Specify ) :
Name of Injured
Age : ____
Sex : ____
Location of Injury
No !
Yes !
No !
Yes !
No !
No !
Yes !
No !
2. Name :
( Signature ) :
Date :
( Signature ) :
Date :
( Signature ) :
Date :
Copy distribution :
( Signature ) :
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
ACCIDENT INVESTIGATION
(CSC-01-R1-AI NO.__________)
Name of Injured
Age : _____
Sex : _____
Accident details ( CSC-01-R1-Accident Report (AR) No. ___________)
Name of Contractor
Yes !
No !
Investigating Person
Site Manager
_____________________________
Name
_____________________________
Name
___________________________
Name
Date :
Date :
(Signature)
(Signature)
Copy distribution :
Date :
(Signature)
SBU
! Fire / Explosion
! Mechanical
! Collapse of Structure
! Others ( Specify ) :
Name of Contractor
Whether the unsafe practice / Act / Condition was informed to the person/s involved or contractor supervisor or L&T
engineer before filling the form :
! Yes
! No
To whom reported ( Give name of persons ) :
________________________________________
Name
Date :
( Signature )
Date :
Copy distribution :
( Signature )
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
(CSC-01-R0- FAAR)
Sr.No. Date
Time
Name of Injured
Sex
Age
SBU
Name of Contractors
1.
2.
3.
Sr.
No.
Type of Injury
Location of Injury
Deviation in Safety
norms
1.
2.
3.
Brief description about accidents :
1.
2.
3.
Unsafe act
Unsafe Condition
1.
1.
2.
2.
3.
3.
____________________________________
NAME OF REPORTING SUPERVISOR / SSO
DATE:
___________
SIGNATURE
____________________________________
NAME OF RCM
DATE:
Copy distribution :
Note :
___________
SIGNATURE
E & C Division
3.8
SHE Manual
SHE Audit
In order to ensure that the site follows all the statutory
requirements, codes and norms, periodic monitoring is required.
The regular and periodic monitoring is also required to find out the
introduction of any makeshift repairs and changes to temporary
construction at work site, which if left unnoticed may lead to
potentially dangerous work situations resulting in losses.
The regular and thorough inspection activities which an operation
undertakes on a frequency consistent with the risk, provides a way
to reduce the potential for these losses through the identification,
analysis and correction of work place hazards before incident
occurs.
Periodic measurement or Audit is more thorough than regular
measurement or Inspection. It takes more time and it measures
the sites complete SHE management System. Unlike the
Inspection, which is of specific nature, the Audit covers the entire
SHE Management System.
The formats that are in use are given in the annexure
At the end of each chapter, wherever necessary formats are given
for inspection / audit for ensuring the safety of the machinery used
or the method adopted.
45
Sheet 1 of 6
AUDIT CHECKLIST
SITE :
AUDITOR :
DATE :
SR.
NO.
1.
2.
3.
4.
5.
6.
7.
SIGNATURE OF AUDITOR :
AUDITEE :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
Sheet 2 of 6
SR.
NO.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
SIGNATURE OF AUDITOR :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
Sheet 3 of 6
SR.
NO.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
SIGNATURE OF AUDITOR :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
Sheet 4 of 6
SR.
NO.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
SIGNATURE OF AUDITOR :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
Sheet 5 of 6
SR.
NO.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
SIGNATURE OF AUDITOR :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
Sheet 6 of 6
SR.
NO.
60.
Are accident prevention tools & safetyrelated items available at site as per
procedure CSC-08?
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
SIGNATURE OF AUDITOR :
ACTIVITY
COMPLIANCE
YES / NO
NON
COMPLIANCE
NOTE NO.
SIGNATURE OF AUDITEE :
REMARKS
E & C Division
SHE Manual
3.9
SHE Training:
3.9.1
(A)
Objective
Awareness of safety in construction, and knowledge about
hazards and their elimination/ minimisation in construction
activities is one of the prime functions of Resident Construction
Manager/ Engineer (RCM/RCE). This awareness is essential to
prevent accidents to man, machine and environment under his
control & responsibility.
In order to prevent accidents, RCM/RCE has to put his
knowledge about safe practices into action, to begin with
himself, and then ensure that safe practices are followed by all,
who are working at his site and particularly by workmen, who
actually carry out the construction activities.
Due to the typical nature of construction activities/sites,
knowledge, culture, skills and attitudes of workmen to safety
vary from site to site and it is necessary for RCM/E to impart to
workmen the knowledge and skill about safe practices in
construction activities, in general and specific to his site.
One of the effective methods, to inform workmen about safe
practices in their work is TOOLBOX TALK/ MEETING. In these
meetings/ talks workmen are informed about hazards involved
in the activities and safe methods of carrying out these
activities. The information must be given regularly, well in time
and in sufficient details. Annexure gives various topics that
could be included in such talks.
(B)
Procedure
This procedure spells out the requirement of conducting TOOLBOX TALKS (TBT) at E & C divisions sites, their timings, their
frequency, subjects and responsible person/s. The Annexure to
the procedure gives Tool-Box Talks details for some of
construction activities, which are normally done at almost all
construction sites.
Steps to be taken by RCM/RCE to implement this procedure are
as follows:
46
E & C Division
1.
2.
3.
4.
5.
6.
7.
SHE Manual
47
E & C Division
(C)
SHE Manual
Administration
1.
2.
3.
48
E & C Division
3.9.2
SHE Manual
Training at site:
Introduction
An effective accident prevention and occupational health hazard
control program is based on proper job performance. When
people are trained to do their job properly, they will do them
safely. Also training is the only way to influence human behavior.
Training Needs
A training program is needed
49
E & C Division
SHE Manual
50
E & C Division
SHE Manual
Annexure 1
Safety philosophy
Material handling
Crane safety
Fire safety
51
E & C Division
SHE Manual
Annexure - 2
52
E & C Division
SHE Manual
Session 8
Industrial Housekeeping
Results of good housekeeping. The responsibility
of the supervisor. OSHA requirement.
Session 9
Material Handling and Storage
Lifting and carrying, handling specific shapes.
Hand tools for material handling. Motorized
equipment. Hazardous liquids and compressed gases.
Session 10
Guarding Machines and Mechanisms
Principles of guarding. Benefits of good guarding.
Types of guards. Standards and codes. OSHA regulations.
Session 11
Hand and Portable Power Tools
Selection and storage. Training in the safe care
53
E & C Division
3.10
SHE Manual
Objectives :
At L&T - E & C Division construction sites, numerous activities carried out
by L&T and its contractor/sub-contractor personnel need to be done
safely to prevent accidents to men, machine and surroundings. The
Construction Safety Manual of E & C Division lays down the basic and
minimum requirements related to safety from those involved in these
activities.
However, it is necessary to ensure that there is commitment from the
Managers / Engineers / Supervisors of persons who carry out these
construction activities. Such commitment can be obtained, if standard
and specific safety instructions related to the activities are informed, in
writing to the Managers / Engineers/ Supervisors before commencement
of the activities on each day and they accept the instructions, in writing.
The commitment to follow safety instructions, in writing, is obtained
through Permit System, which has to commence from the day the first
construction activity starts at site until the last activity. The Permit
System is applied to those activities wherein there are higher potential
risks and hazards. These generally are:
-
Procedure :
This procedure lays down steps to be taken by RCM/ RCE before and
during the above mentioned activities at construction site.
SHE Organisation & Management
54
E & C Division
SHE Manual
There are five different Permit forms, each dealing with one of the five
activities mentioned above. Each form has certain standard instructions
and space for writing special instructions by RCM/ RCE, related to the
activity and site situation. These instructions have to be clearly
understood by the workers, Manager/ Engineer/ Supervisor and ensured
that they are followed by the persons actually carrying out the concerned
activity. The forms, therefore, require signatures of concerned responsible
persons, implying their commitment to the instructions. The forms also
require communication regarding completion of the permitted activities.
After a form is returned stating completion of an activity, the same can
not be carried out again unless the permit is renewed. The permit can be
renewed for maximum 6 days only. Thereafter a fresh permit is required.
Annexure - I to this procedure lists construction activities that require
issue 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 and
advise them in writing (by letters and notices) that permits are
required to carry out the above mentioned five activities.
2.
3.
RCM/ RCE shall issue the requisite permit form noting down special
instructions and if instructions, if any to the contractors supervisor,
who will sign on the form as the Initiator.
4.
After the site and persons are ready as per the instructions on the
form, RCM/RCE, shall inspect the work-site and persons for
compliance of the instructions and if instructions are fully complied,
the contractors supervisor, RCM/RCE, L&T Engineer and SSO shall
sign the form to permit the form to permit the activity for the period
and date mentioned on the form.
5.
55
E & C Division
SHE Manual
immediately by stating the reason and signing the permit, if they find
any deviations during the progress of work. The same activity can be
carried out again by obtaining a fresh permit from RCM/ RCE.
6.
7.
8.
9.
56
E & C Division
SHE Manual
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/ RCEs opinion require a permit.
Safety Officers/ Auditors from Powai will inspect/ audit this aspect
when they visit the site.
Annexure 1
Table for ready reference :
Activity/
Applicable Permit
Type of work
CSCR
CSCP
CSCW
Working at height
Drilling/ grinding
Working
eqpt.
on
electrical
Operating
tools
pneumatic
Hydraulic/
testing
Pneumatic
CSCL
Radiography/ N. D. T.
Sand
blasting/
blasting
CSCC
of
Spray painting
Manual painting
Note :
* Some times more than one permit is required. While doing
grinding work in confined space requires hot work permit as well
as permit for entry into confined space.
57
Permit No.: -
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
1.
2.
3.
Name of Contractor :
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
17
14
18
19
20
21
N/A
Time / Period
Remarks
From
To
Signature of
Site Engineer
Signature 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.
All the points mentioned in the above checklist have been checked & found OK
____________________________________
___________________
________________
(L&T Engineer)
(L&T-S.S.O.)
________________________
(RCM / RE L&T)
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________
_____________
__________
(L&T Engineer)
(L&T-S.S.O.)
____________
( RCM / RE L&T)
Permit No.: -
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons entering into confined space
4.
5.
6.
Name of stand by Person:
1.
2.
3.
Name of Contractor :
Item
N/A
12
13
14
15
16
9
10
11
N/A
Testing Record
Date of
Work
Time / Period
From
To
Meter Reading
Flammability
%
O2
Content %
Toxic Gases
PPM
Signature of
Signature of
Site
RCM/RE
Engineer
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.
All the points mentioned in the above checklist have been checked & found OK
____________________________________
___________________
________________
(L&T Engineer)
(L&T-S.S.O.)
________________________
(RCM / RE L&T)
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________
___________________
________________
(L&T Engineer)
(L&T-S.S.O.)
________________________
( RCM / RE L&T)
Permit No.: -
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
1.
2.
3.
Name of Contractor :
N/A
*13
Item
14
15
16
17
18
19
20
N/A
Additional permit required and / or attached:- No Yes ( If yes specify:Daily Visual Inspection
Date of
Work
Time / Period
From
To
Remarks
Signature of
site engineer
Signature of
RCM/RE
)
To be signed only after completing the job
Signature of site
Signature of
engineer
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
All the points mentioned in the above checklist have been checked & found OK
__________________
__________
________
____________
(L&T Engineer)
(L&T-S.S.O.)
(RCM / RE L&T)
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
______________________
_________
________
_____________
(Contractors Site Incharge)
(L&T Engineer)
(L&T-S.S.O.)
( RCM / RE L&T)
Permit No.: -
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons involved in Hot work
4.
5.
6.
Name of Incharge:
The following items must be checked before issuing the permit
1.
2.
3.
Name of Contractor :
Item
1
2
3
4
5
6
7
8
9
10
N/A
Item
11
12
14
15
16
17
18
19
20
13
N/A
Testing Record
Date of
Work
Time / Period
From
To
Meter Reading
Lower Explosive
Limit %
Upper Explosive
Limit %
Signature of
Site
Engineer
Signature
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.
All the points mentioned in the above checklist have been checked & found OK
____________________________________
___________________
(L&T Engineer)
_______________
(L&T-S.S.O.)
________________________
(RCM / RE L&T)
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________
___________________
________________
(L&T Engineer)
(L&T-S.S.O.)
________________________
( RCM / RE L&T)
Permit No.: -
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Location of work :________________________________________________________________________________
Source strength: ___________________________________
Curie: ____________________________________
1.
2.
3.
Name of Contractor :
Name of Radiography agency :
N/A
Item
6
7
N/A
Time / Period
Remarks
From
To
Signature of
Site
Engineer
Signature
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.
All the points mentioned in the above checklist have been checked & found OK
____________________________________
___________________
(L&T Engineer)
_______________
(L&T-S.S.O.)
________________________
(RCM / RE L&T)
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________
___________________
________________
(L&T Engineer)
(L&T-S.S.O.)
________________________
( RCM / RE L&T)
E & C Division
3.11
(A)
Objective
SHE Manual
Procedure
This Procedure sets out safety guidelines and working procedures
which 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 supplement
the applicable laws and regulations and state some of the practices
required of `visitors on L&T E & C Division construction sites.
Term `visitors includes all persons who are not regularly
employed by (registered/on the role of) L&T or its contractors/subcontractors, i.e. `visitors include all persons who enter L&T sites
for discussion and/or for carrying out work/activity on behalf of
suppliers/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 steps
are taken whenever he permits a visitor into his construction site.
1.
2.
58
E & C Division
3.
4.
SHE Manual
5.
6.
7.
59
E & C Division
SHE Manual
60
E & C Division
SHE Manual
Annexure -1
61
E & C Division
SHE Manual
E & C Division
SHE Manual
WORKER
PERFORMANCE
EQUIPMENT
ENVIRONMENT
T
A
S
K
E & C Division
SHE Manual
WORKER
PERFORMANCE
EQUIPMENT
ENVIRON
MENT
A
C
C
I
D
E
N
T
T
A
S
K
E & C Division
SHE Manual
RECOGNISE
EVALUATING,
ELIMINATING,
or at least reducing, the destructive effects of hazards emanating from
human errors and from the situational and environmental aspects of
the work place. Its primary function is to locate, assess, and set
effective preventive and corrective measures for those elements
detrimental to operational efficiency and effectiveness.
The process exists on three levels, namely National (laws, regulations
etc), Organisational (management of hazard control Programmeme,
safety committees etc) and component (worker equipment
environment).
E & C Division
SHE Manual
E & C Division
SHE Manual
Company policy
Identification and
evaluation of hazards
Programme objective
Monitoring Programmes
Assignment of
Responsibility and Authority
Maintenance programmes
Housekeeping
HAZARD
Standard compliance
Accident Investigation
CONTROL
PROGRAMME
Evaluation of Programme
effectiveness
E & C Division
5.
5.1
Site layout
SHE Manual
E & C Division
5.2
SHE Manual
CONSTRUCTION DETAILS:
These will enable the proper utilisation of the space, unnecessary wastage
of material due to prolong storage, maintenance of better housekeeping
and hiring of costly equipment and skilled personnel for a minimum
period.
5.3 IN BUILT SAFETY MEASURES:
At the planning stage itself safety should be integrated in all the planned
activities. The material for construction, the machinery to be used and
the method of construction should all be evaluated with reference to the
site, the type of people to be engaged, the infrastructure available and
the environmental conditions and adequate in built safety measures and
work methods should be evolved.
Other measures like Safety Indoctrination and Safety Education,
delegation of safety responsibilities down the line, integration of safety
into operating methods and procedures will improve the quality of work
and help in preventing accidents and dangerous occurrences at the site.
Site planning and layout
E & C Division
SHE Manual
2.
Work areas: loose materials, scrap, tools, etc shall not be allowed
to be lying in the working areas especially in the vicinity of ladders,
ramps stairs, etc. This is more important at heights where the loose
materials are liable to fall down.
Spills of oil and grease should be removed immediately.
An effective means like provision of receptacles should be provided
to store waste and scrap pieces.
3.
4.
Scrap yard : Wooden scrap yard should be well away from any
gas 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 reasonable
time.
E & C Division
SHE Manual
5.
6.
7.
The approach road from and to the work site shall never be
blocked by parking vehicles or stacking materials, etc. thus
blocking the movement in case of emergencies.
E & C Division
5.5
SHE Manual
SAFETY AT STORES:
E & C Division
6.
Civil work
6.1
Blasting
SHE Manual
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:
Civil Work
E & C Division
SHE Manual
body truck, a fire & waterproof tarpaulin shall be used to cover the
explosives.
6.1.4 Storage
While taking explosives for actual usage, it shall not be placed near
sources of heat or water.
Civil Work
E & C Division
SHE Manual
Replace the cover of the case after the required quantity of explosive
is taken out.
Only fuse and nothing else shall be inserted in the open end of the
blasting cap.
No. holes should be loaded except those that are to be fired in the
next round of blasting. Holes loaded during one shift should be fired
on the same shift.
To avoid misfires, the detonator should be completely inserted length
wise in the cartridge, fastened in such a manner that it cannot be
pulled out accidentally.
Civil Work
E & C Division
SHE Manual
Blasting should be carried out only during lean hours - say during
lunch time, night hours, etc.
6.1.7 Tamping
Only wooden tamping tool should be used; if metallic parts are used,
they should be of non-sparking type. Primer should never be tamped.
Civil Work
E & C Division
SHE Manual
25
50
100
250
500
1000
2500
5000
10000
25000
50000
100000
of
different
Min.distance(feet)
100
150
220
350
450
650
1000
1500
2200
3500
5000
7000
1
10
30
60
Civil Work
10
30
60
250
5
10
15
30
E & C Division
SHE Manual
6.1.9 Misfires:
There is no absolute safe method for handling misfires. But misfires can
be prevented,
i
ii
iii
Civil Work
2.
3.
4.
5.
6.
7.
8.
9.
No
NA
E & C Division
6.2
SHE Manual
Excavation:
To prevent injury and property damage during excavation work,
make adequate` protective measures part of the job. Study preexcavation condition, such as superimposed loads, soil structure,
and hydrostatic pressure. From such a study, it is possible to
evaluate changes that might occur, to prepare for situations that
might develop, and to plan the job ahead. Excavation permits
should be used to ensure that all the necessary precautions are
taken to protect employees.
Underground Utilities
A major hazard in urban or built-up areas is the presence of
underground facilities, such as utility lines (water, electric, gas, or
telephone), tanks, process piping, and sewers. If this equipment is
dug into, undercut or damaged in any way, there may be injury or
death 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 utilities
can be identified and all underground utilities will be marked.
Before starting operations, consult the company or plant engineer,
the utility companies, engineers, and the citys or towns engineers.
The location of various facilities and their approximate depth below
ground must be determined and marked by stake in the ground or
by marking on the floor.
Electronic locators can be especially helpful where an excavation
would cross numerous buried obstacles. If the facilities are to be
left in place, they must be protected against damage and
sometimes also against freezing.
Indicate the contents of buried tanks and piping on the location
markings. If the contents are flammable or toxic, have proper
protective equipment readily available in case of rupture. Also
indicate the bottom depth of tank.
Do the allow any shovel, dragline or other digging machine to
Civil Work
E & C Division
SHE Manual
Civil Work
E & C Division
SHE Manual
E & C Division
SHE Manual
10
E & C Division
SHE Manual
Civil Work
11
E & C Division
6.3
SHE Manual
Piling :
Piling work is an integral part of any construction activity. If this
activity is not carefully prepared and executed, it can result in
delay as well as causing serious accidents. The Building and Other
Construction Workers ( Regulation of Employment and Conditions
of Service ) Rules, 1998 ( Rules 214 to 222 ) give detailed
statutory requirements to be complied with while doing the piling
work. It is advisable to adhere to certain basic safety measures
which are given below:
2.
3.
There should be a firm level base for the crane, or crane mats
provided;
4.
5.
6.
7.
Civil Work
12
E & C Division
SHE Manual
9.
10.
2.
3.
4.
5.
While the workers are working down a bore hole they must
wear a safety harness
6.
Civil Work
13
E & C Division
SHE Manual
7.
8.
9.
Civil Work
14
E & C Division
6. 4.
SHE Manual
Civil Work
15
E & C Division
SHE Manual
6. 4. 2. Ladders
Ladders should conform to the provisions given under Rules 172
to 174 of The Building and other Construction Workers
(Regulation of Employment and Condition of Service ) Central
Rules, 1998.
Ladders may be classified under two broad categories Portable
and Fixed.
Single Ladders
These are as single unit and intended to be used as such. The rungs are
generally round or horizontal in cross section.
Some ladders are provided with flat plates in which case they are called
stepladders. B.I.S.4435: 1967 specifies that the treads should be
horizontal, when the ladder is inclined at an angle 650 750 to horizontal.
Where ladders can not be placed directly then retaining hooks or devices
should be provided on top of the ladder.
Some of the dos and donts while using single ladder are given in
annexure-1.
Civil Work
16
E & C Division
SHE Manual
Working on Roof :
Some accidents happened due to fall of persons working on roof. Fall
through fragile roof sheeting, loss of balance due to steep slope of the
roof and insufficient care while working at the edge of the roof constitute
the principle causes for these accidents which could be prevented by the
safety measure given below.
Roofs covered with asbestos sheets, roof light covering glass or perspex
can break under the weight of the person and working along perlins can
not 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 least
3.2cm thick and with a gap between them not more than 38cm.
The ladder should be of sufficient to withstand the weight of the person
and the material he carries, when spanning across the points of support
on the roof.
It is not safe to fix the headboard or anchor board to the ladder by nails
alone. Designs of wooden and metal ladders are given in annexure-2.
A common mistake in securing the roof ladder is to allow the anchor
board or other anchorage to bare on the ridge capping. The capping may
break off if it is off brittle material or the anchorage may slip away. The
right method is to have the anchorage to bear on the opposite slope or to
be secured by other means such as rope.
For curved roofs, special ladders to suit the shape of the roof will have to
be 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 of
respective person) can help to ensure that persons are not allowed to
work on roof without adhering to the above safety precautions. (a model
work permit is given in annexure-3).
Civil Work
17
E & C Division
SHE Manual
Civil Work
18
E & C Division
SHE Manual
If
If
If
If
If
a
a
a
a
a
platform
platform
platform
platform
platform
Civil Work
is
is
is
is
is
used
used
used
used
used
19
E & C Division
SHE Manual
should
conform
to
the
Safety Belts
There are many situations where it may not be practicable to provide all
the normal measures to protect persons falling from heights. In such
cases, the persons should wear safety belts secured suitably through a
line to a proper anchorage.
Civil Work
20
E & C Division
SHE Manual
There are four common types of safety belts namely, Pole safety belt,
General purpose safety belt, General purpose safety belt with remote
anchorage and Harness (Man hoisting) type safety belt.
The material of the safety belt which should be chosen (leather and
webbing of natural and man-made fibers) according to the job
requirements.
Lifelines should be secured to permit as little slack as possible.
In case of obstruction for free fall, shock absorbers should be provided
for 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 is
possible, unless shock absorber is provided. The belts should be
maintained properly with periodic inspections.
Annexure-5 gives important standards, convention pertaining to this
chapter.
Civil Work
21
E & C Division
SHE Manual
Annexure 1 (Ladders)
Civil Work
22
ACCESS / EGRESS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Remarks
House Keeping
1.
2.
3.
4.
5.
E & C Division
6.5
SHE Manual
Demolition of Structures
Plant personnel should do only minor demolition. Employ specialists
in the field if structures to be removed look as though they will
present a problem. Wrecking specialists are familiar with the
procedures and precautions necessary to do the wo0rk safely.
They know how to protect the public and adjacent property, and
they know the applicable federal, state or provincial, and municipal
codes and regulations.
Following are minor demolition work:
Civil Work
23
E & C Division
SHE Manual
6.6
Carpentry Workshop
6.6.1
Plant Layout :
The following general principles should be followed while siting
the machinery:
6.6.2
Housekeeping :
Civil Work
E & C Division
6.6.3
Machinery :
6.6.4
SHE Manual
Operator :
The Carpentry in-charge should nominate the required number of
operators who will be authorised to work on the wood-working
machines. Their names must be displayed on a board near the
machine with a statement saying no other is authorised to work
on the machine.
The designated operator shall be employed after he has been
sufficiently trained to work on the wood working machinery and
he should be adequately instructed as to the inherent dangers
involved in the operation.
6.6.5
6.6.6
Lighting :
25
E & C Division
SHE Manual
ANNEXURE 1
SUMMARY OF SAFETY RULES FOR VARIOUS WOODWORKING
TOOLS
Every operator should be trained in the safety rules covered in this
chapter. As a summary, safety rules that demand close attention are
listed 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 for
ripping
Stock firm to fence
Remove rip fence for crosscuts
Blade guards
CIRCULAR SAW
Blade guards
Binding
Blade-correct type
No obstructions
Civil Work
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 the
underside of stock
Spindle nut tight
Shape only pieces 10 in. or longer
Proper types of cutters
SANDER
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
26
E & C Division
SHE Manual
Narrow strips thicker than the auxiliary fence-work support may enter the guard and strike the
baffle.Carefully raise the guard only enough to clear the workpiece. Use the push block to complete the cut.
Civil Work
27
E & C Division
SHE Manual
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 wood
acting as a Positive stop against the end of the workpiece; the hold down is flat on the bottom, Both are used to
keep the operator's thumbs and fingers away from the cutter head.
Civil Work
28
E & C Division
SHE Manual
Civil Work
29
E & C Division
6.7
SHE Manual
Grinding Operation:
Introduction
The commonly used grinding m/c s in construction are the
portable grinding m/cs. The speed of the wheels ranges from
7000 rpm to 14000rpm or sometimes more than that. Even a
minor mishandling would lead to a serious mishap. Hence
grinding operation ought to be done by a trained operator
following the safety norms.
Grinding is a hazardous operation. The grinding wheel rotates at
a speed of more than 7000 rpm that cause a very serious injury
Grinding machines shape material by bringing it into contact with
a rotating abrasive wheel or disk. Grinding includes surface,
internal, external cylindrical and centerless operations, as well as
polishing, buffing, honing, and wire brushing. Portable machines
that use small, high-speed grinding wheels have been dealt
under Hand and Power Tools.
6.7.1
Civil Work
E & C Division
6.7.3
SHE Manual
6.7.3
Civil Work
31
E & C Division
SHE Manual
and disks of various grades and sizes have different pitches. (ring
test 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 points
shown in Figure.
Thoroughly investigate grinding wheel and disk failures,
preferably with the manufacturer's representative. This type of
investigation, along with immediate corrective action, greatly
reduces the possibility of recurrent failures.
6.7.4
6.7.5
Civil Work
32
E & C Division
SHE Manual
speed use. The grinding wheel must be rated at the same RPM
as the machine or more than the machine rpm. If it is not, the
wheel may explode and throw particles into the work area
causing serious at times fatal injuries.
Mounting wheels :
Mount all abrasive wheels between flanges. Exceptions to this
rule include mounted wheels, threaded wheels (plugs and cones),
plate-mounted wheels, and cylinder, cup, or segmental wheels
mounted in chucks.
Flanges should have a diameter not less than one-third of the
wheel's diameter. Flanges for the same wheel should be of the
same diameter and thickness, accurately turned to correct
dimensions, and in balance. The requirement for balance does
not apply to flanges made out of balance to counteract an
unbalanced wheel.
Key, screw, shrink, or press the inner or driving flange onto the
spindle. The bearing surface of the flange should run true with
the spindle. The outer flange's bore should easily slide onto the
spindle. (hand tightening , blotter paper)
Schedule flange inspections frequently. Remove from the spindle
a flange found to be sprung, not bearing evenly on the wheel, or
defective in any other way. Replace it with a flange that is in
good condition.
An incorrectly mounted abrasive wheel is the cause of much
wheel breakage. Since rotational forces and grinding heat cause
high stresses around the wheel's central hole, follow safety
regulations concerning size and design of the wheel.
Civil Work
33
E & C Division
SHE Manual
GRINDER CHECKLIST
TYPE _____________
SIZE ______________
RPM ________
PERIPHERAL SPEED________
Item
OK
NOT OK
DEPARTMENT ________
INSPECTED BY _____________
Civil Work
34
E & C Division
SHE Manual
Safe Speeds :
Do not operate abrasive wheels and disks at speeds exceeding
those recommended by the manufacturer.
In particular,
unmarked wheels of unusual shape, such as deep cups with thin
walls or backs with long drums, should be operated according to
the manufacturer's recommendations.
As the wheel wears down, the spindle's speed (rpm) sometimes
increased to maintain the surface speed (sfpm). When the wheel
is nearly worn down, the spindle is running at the highest rpm.
When the worn wheel is replaced, adjust the spindle's speed. It is
not possible and there is no need of adjustment of the spindle. If
the spindle's speed is not adjusted, the new wheel might break
because
the
surface
speed
exceeds
manufacturer's
recommendations.
Civil Work
35
E & C Division
SHE Manual
Civil Work
36
E & C Division
6.7.9
SHE Manual
Work Rests :
Because work has become wedged between the work rest and
the wheel, many bench and floor-stand grinder wheels have
broken, thus causing serious injury. The work rest should be
substantially constructed and securely clamped not more than
1/8 in. (3.2 mm) from the wheel. Check the work rest's
position frequently. The work rest's height must be on the
horizontal centreline of the machine's spindle.
Never adjust the work rest while the wheel is in motion. The
work rest might slip and strike and break the wheel, or the
operator might catch a finger between the wheel and the work
rest. To prevent work from adding twisting and bending stress
to the wheel, operators should use guides to hold the work in
position when slot grinding or performing similar operations.
DRESSING ABRASIVE WHEELS
Abrasive wheels that are not true or not in balance will produce
poor work. They can damage the machine and injure the
operator. Keeping the wheels in good condition eliminates
these possibilities, decreases wheel wastage, and lengthens the
wheel's life.
To recondition a rutted or excessively rough wheel, often it is
necessary to dress it by removing a large area of the face.
Equip wheel-dressing tools with hood guards over the tops of
the cutters. They will protect the operator from particles flying
from the wheel or pieces of broken cutters. The operator of a
wheel dresser should use a rigid work rest set close to the
wheel. The operator should move the wheel dresser back and
forth across the wheel's face, while firmly holding the heel or
Lug-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 if
necessary. Wheels that are too worn, or too out of balance, to
be balanced by truing or dressing should be taken out of
service.
Civil Work
37
E & C Division
SHE Manual
Civil Work
38
E & C Division
SHE Manual
39
E & C Division
SHE Manual
40
E & C Division
SHE Manual
Civil Work
41
E & C Division
SHE Manual
Grinding Wheel
Grinding Wheel
Undercut
necessary
for firm fit
Wheel Blotter
Flange Recessed
Wheel
Spindle
Wheel Spindle
Inner flange keyed screwed,
shrunk or pressed
Blotter
Wheel easy
fit on flange
shoulders
Civil Work
42
E & C Division
SHE Manual
Civil Work
43
E & C Division
6.8
SHE Manual
2.
3.
4.
5.
Civil Work
E & C Division
6.
SHE Manual
45
E & C Division
SHE Manual
Civil Work
46
E & C Division
7.
SHE Manual
Mechanical works:
At any construction site, the main activity will be handling of
material either manually or with mechanical means. About 80% of
the accidents occur while doing this activity.
This chapter
exclusively deals with problems encountered while undertaking the
above task.
Mechanical Works
E & C Division
SHE Manual
Mechanical Works
E & C Division
SHE Manual
Mechanical Works
E & C Division
SHE Manual
Mechanical Works
E & C Division
SHE Manual
Frozen tissues are painless and appear waxy and yellow. They
will become swollen and painful and prone to infection when
thawed. Do not re-warm rapidly. Thawing may require 15 to
60 minutes. For white people, thawing should continue until
the pale blue tint of the skin turns pink or red. For black
people, assess frostbite by the swelling and blistering of the
skin. Reduction of swelling indicates alleviation of frostbite.
Morphine or tranquillisers may be required to control pain
during thawing and should be administered under professional
medical supervision.
If the frozen part of the body thaws before the doctor arrives,
cover the area with dry, sterile dressings and a large, bulky
protective covering.
Mechanical Works
E & C Division
SHE Manual
7.1.1 Winch :
Crabs and Winches may be either hand operated or electrically
driven. Some form of braking or safety lowering device should be
installed, and portable units should be installed securely against
the pull of the hoisting rope or chain.
Under Rule 59, The Building and Other Construction Workers
(Regulation of Employment and Conditions of Service) Central
Rules, 1998 provides the statutory requirements to be complied
with while using the winch. A schematic diagram of the winch is
given below
Mechanical Works
E & C Division
SHE Manual
Mechanical Works
E & C Division
SHE Manual
7.1.2 Reeving :
If more than one tackle block is used in material handling, the
process of connecting them is termed as REEVING;
Block and Tackle :
A safety factor of 10 is recommended for determining the safe
working 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 of
the load that can be handled by the rope multiplies but does not
correspondingly increase the strength of the blocks. Calculations
show that, in most instances, using a safety factor of 10 for the
rope automatically makes the load on the blocks correspond to the
rope size within safe work load limits. (Mark blocks with their safe
working load. as specified by their manufacturers.) The total weight
on the tackle should never exceed this safe load limit. The safe
work loads for rope used in block-and-tackle assemblies conversely
1 / 10th of the block's breaking strength, based on a safety factor
of 10.
To find the required breaking strength for new rope, proceed as
follows:
1.
2.
3.
Mechanical Works
E & C Division
2.
3.
4.
SHE Manual
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 (the
number of parts at the movable block) = 700 lb (3 1 8 kg).
Applying the safety factor of 10 (10 x 700) gives 7,000 lb
(3,200 kg), the required breaking strength of the rope.
New Manila rope of 7/8 in. (22 cm) has a breaking strength of
7,700 lb (3,500 kg) and, therefore, is the proper size for the
load. Synthetic fibres would have greater tensile strength.
The safe work load limit for two double blocks made for rope Of
7/8- in. (22-cm) diameter is 2,000 lb (900 kg)-the equivalent of
the 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 upper
hook of a set of falls as a precaution against its accidental
detachment.
Inspect blocks thoroughly and frequently,
attention to parts that are subject to wear.
paying
particular
Mechanical Works
E & C Division
SHE Manual
7.1.3 Rigging:
In lifting the various materials and supplies, a number of standard
chokers, slings, bridle hitches, and basket hitches can be used.
Because loads vary in physical dimensions, shape, and weight a
rigger needs to know what method of attachment can be safely
used. It is estimated that at least about 15 to 50% of the crane
accidents are due to improper rigging.
The contractor needs to train those employees who are responsible
for rigging loads about the :1. Knowledge of the load
2. Judgement of distance
3. Selection of tackle and lifting gear
4. Proper operational directions to be given.
The most important rigging precautions are to determine the
weight and the size of the load before attempting to lift it. This will
determine the type of equipment and gear to be used and the
method of slinging.
There are various methods of hitching the load to the hook through
choker hitch, basket hitch etc. Some of the types of hitching /
slinging are given below: Watch for
broken wires in
Mechanical Works
10
E & C Division
SHE Manual
The fiber, wire ropes and chain slings attachments are dealt under
appropriate headings.
Mechanical Works
11
E & C Division
SHE Manual
Method of Attachment:
All hooks and rings used as sling connections should develop the full rated
capacity of the sling.
Sockets and compression fittings, when properly attached with wire rope
sling should develop 100% of the rated strength of the wire rope. Swaged
sleeve sling endings should develop 92 to 95% of the wire ropes strength.
Compression fittings and swaged sleeve fittings are available from the
wire rope manufacturers.
Hand tucked splices develop about 90% of the ropes strength in ropes
having diameter less than and 80% for larger diameters.
The recommended load rating for a sling assembly is usually based on 1/5
the 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, or
equivalent, heat treatable alloy steel as the chain itself. In most cases the
attachments are provided by the manufacturers themselves.
When rigging irregular shaped loads or heavy loads proper rigging should
be made. Some of the special rigging methods are shown below: -
Identification
tag
Safety lock
Mechanical Works
12
E & C Division
SHE Manual
1 - Single Vertical
Hitch
Mechanical Works
13
E & C Division
Single Double
Wrap Basket Hitch
SHE Manual
This hitch
compresses the
load and prevents
it from slipping
out of the slings.
Pair of Double
Wrap Basket
Double choker
Use to turn loads
Not recommended
Recommended
Right
Wrong
Chokers do not provide full support for loose loads
Material can fall out.
Single Choker Hitches
Mechanical Works
14
E & C Division
SHE Manual
Load held on
Two part of
rope
Load held on
one part of rope
Packers to
prevent
chafe
Packers to
prevent
chafe
Mechanical Works
15
E & C Division
SHE Manual
Sling Calculation: -
Mechanical Works
16
E & C Division
SHE Manual
Wear
Surfa
Mechanical Works
17
E & C Division
SHE Manual
Mechanical Works
18
E & C Division
SHE Manual
several
and jerky
to avoid
following
operations
operation,
these and
rules are
1.
2.
Centre the crane over the load before starting the hoist to avoid
swinging the load as the 1ift is started. Loads should not be
swung by the crane to reach areas not under the crane ( Figure
below )
3.
4.
Never lower the block below the point where less than two full
wraps of rope remain on the hoisting drum. Should all the rope
be unwound from the drum, be sure it is rewound in the correct
direction and seated properly in the drum grooves, otherwise
the rope will be damaged and the hoist limit switch will not
operate to stop the hoist in the high position.
5.
Mechanical Works
19
E & C Division
SHE Manual
Do not make lifts beyond the rated load capacity of the crane,
sling chains, rope slings, etc.
7.
8.
Make certain that before moving the load, load slings, load
chains, or other load lifting devices are fully seated in the
saddle of the hook.
9.
10. On all capacity or near capacity loads, the hoist brakes should
be tested by returning the master switch or push button to the
OFF position after raising the load a few inches off the floor. If
the hoist brakes do not hold, set the load on the floor and do
not operate the crane. Report the defect immediately to the
supervisor.
11. Check to be sure that the load is lifted high enough to clear all
obstructions and personnel when moving bridge or trolley.
12. At no time should a load be left suspended from the crane
unless the operator is at the master switches or push button
with the power on, and under this condition keep the load as
Mechanical Works
20
E & C Division
SHE Manual
Mechanical Works
21
E & C Division
SHE Manual
Mechanical Works
22
E & C Division
SHE Manual
Mechanical Works
23
E & C Division
SHE Manual
7.1.6. Lifting and carrying of excessive weightAs per Rule 38 of THE BUILDING AND OTHER CONSTRUCTION
WORKERS (REGULATION OF EMPLOYMENT AND CONDITIONS
OF SERVICE) CENTRAL RULES, 1996
An employer shall ensure at a construction site of a building or
other construction work that
(a)
(b)
Mechanical Works
24
E & C Division
7.2.
SHE Manual
Crane Safety
Derricks and Cranes:
Derricks:
The derricks are normally rigged/fabricated at the site to do a
specific repeated type of job like piling operation, within a small
radius of swing. Rules 67 & 68 of THE BUILDING AND OTHER
CONSTRUCTION WORKERS (REGULATION OF EMPLOYMENT AND
CONDITION OF SERVICE) CENTRAL RULES, 1998 give statutory
guidance regarding the construction of the derrick. The following
diagrams show some of the common type of derricks used at
construction site.
Mechanical Works
25
E & C Division
SHE Manual
Frame Derrick
Guy Derrick
Mechanical Works
26
E & C Division
SHE Manual
Mechanical Works
27
E & C Division
JIB CRANE
Mechanical Works
SHE Manual
PILLER CRANE
28
E & C Division
Mechanical Works
SHE Manual
29
E & C Division
SHE Manual
2.
3.
4.
Operators 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 the
crane. 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 boom
including weight of hook block, ropes/slings, etc.
5.
6.
Tag lines should be used while hoisting heavy and bulky materials.
Mechanical Works
30
E & C Division
SHE Manual
7.
The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by Maintenance personnel to ensure
the crane's safe operation.
8.
9.
The boom or any part of the crane should not come near any live
electric line/service line.
10.
11.
12.
13.
The operator should be able to see the hook and load throughout the
hoisting period.
14.
During storm, the hook block should be anchored firmly and swing
lock be released.
15.
When an extended boom is used on the crane, the operator must use
extreme care in lowering load to the ground. An extended boom
never should be lowered to one side of the chassis for the stability of
the crane is usually reduced in that position and the crane will get
over turned.
16.
17.
The use of any make shift methods to increase the capacity of crane
such as timbers, with blocking, or adding counter-weight, should not
be permitted.
18.
Before leaving the crane at the end of the workday, the crane
operator should remove the load from the hook and raise the hook
block to maximum height.
19.
The crane operator should keep the deck clean of any oil, mud and -
Mechanical Works
31
E & C Division
SHE Manual
grease.
20.
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 required
lowest point to ensure that atleast two turns of rope remain on the
drum and to the highest point to check that the drum capacity will not
be exceeded.
Mechanical Works
32
E & C Division
SHE Manual
Mobile Cranes:
Following precautions have to be taken while using, tyre mounted mobile
cranes in addition to the precautions given above.
1.
2.
3.
4.
5.
The Safe working load is generally tabulated in the Load chart of the
crane.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 boom
including weight of hook block, ropes/slings, etc.
7.
8.
The Crane Operator shall respond to signals only from the appointed
signaller but shall obey stop signal at any time no matter who gives
it.
9.
Tag lines should be used while hoisting heavy and bulky materials.
10.
The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by a Maintenance person to ensure the
crane's safe operation.
11.
Mechanical Works
They
33
E & C Division
SHE Manual
12.
The boom or any part of the crane should not come near any live
electric service line.
13.
14.
15.
16.
17.
The mobile crane shall be fitted with suitable horn, Headlights, Side
Lamps, rear and stop lights and flashing direction indicator.
18.
Cranes with cantilever type jib, when travelling without load, the jib
should be lowered to a horizontal position.
19.
Mechanical Works
34
E & C Division
SHE Manual
Crane Operation Daily Checklist
Date
Description
The following applicable items shall be checked daily, other
items may apply.
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%) Max
4.) 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
Item Number
1 2
6 7
Operators
Remark
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Mechanical Works
35
Sign
E & C Division
7.3
SHE Manual
Erection of Structures:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Structural Erection:
1.
2.
Mechanical Works
36
E & C Division
SHE Manual
3.
left
for
easy
handling
and
4.
5.
6.
7.
Care should be taken while lifting loads. Proper tag line must
be used for guiding while lifting loads.
8.
9.
Loose bolt, nuts and tools must be kept in boxes and not on
structures. Boxes must have proper anchorage.
37
E & C Division
SHE Manual
Mechanical Works
38
E & C Division
7.4.
SHE Manual
Nylon rope:
Nylon rope has over two and a half times the breaking strength
of Manila rope and about four times its working elasticity. It is,
therefore, well suited to shock loading, such as is required for
restraint lines.
Its resistance to abrasion is remarkably high in comparison to
other ropes.
While nylon rope is wet or frozen, its breaking strength is
reduced by 10% to 15%.
Nylon rope also is highly resistant to organisms that cause
mildew and rotting and to attack by marine borers in sea water.
Mechanical Works
39
E & C Division
SHE Manual
Polyester rope:
Polyolefin rope:
Mechanical Works
40
E & C Division
SHE Manual
Composite rope :
Working Load :
Because the safety factor is not the same for all ropes and is
based upon static loading, caution has to be exercised while
using thumb rule. Also caution has exercised when using the
working load figures supplied by the manufacturer.
Mechanical Works
41
E & C Division
SHE Manual
Mechanical Works
42
E & C Division
SHE Manual
Mechanical Works
43
E & C Division
SHE Manual
Mechanical Works
44
E & C Division
SHE Manual
If possible, do not drag rope since this wears away the outer
fibres. If a rope picks up dirt and sand, abrasion within the
strands of the rope will rapidly wear it out.
Handle twisted rope so it retains the amount of twist (called
balance) that the rope seeks when free and relaxed. If rotating
loads and improper coiling and uncoiling change the balance,
restore it by properly twisting the rope at either end. Severe
unbalance can cause permanent damage; localised over twisting
causes kinking or hocking. Kinking strains the rope and may
over stress the fibres. It may be difficult to detect a weak spot
made 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. Pull
the bottom end up through the coil, and unwind the rope
counter clockwise. If it uncoils in the other direction, turn the
coil of rope over, and pull the end out on the other side.
Avoid sharp bends over an unyielding surface since this causes
extreme tension on the fibres. To make a rope fast, select an
object with a smooth round surface of sufficient diameter.
If the object does have sharp corners, pad the corners.
Thoroughly dry out rope that has become wet; otherwise, it will
quickly deteriorate. Do not allow wet rope to freeze. Hang up a
wet rope, or lay it in a loose coil in a dry place until thoroughly
dry. Rope deteriorates more rapidly if it is alternately wet and
dry than if it remains wet.
Mechanical Works
45
E & C Division
7.4.2
SHE Manual
Wire rope :
Wire rope is more widely used than fibre rope. Wire rope has greater
strength and durability under severe working conditions than does fibre
rope. The physical characteristics of wire rope do not change when
used in varying environments.
Wire rope has controlled and
predictable stretch characteristics.
Construction
Wire rope is composed of steel wires, strands, and core. The individual
wires are cold drawn to predetermined size and breaking loads according
to required grades. Grades include iron, tractor, mild plow steel, plow
steel, improved plow steel, and extra-improved plow steel. The wires
are then laid together in various geometrical arrangements according to
construction requirements for strands and classifications of wire rope (6
x 19, 6 x 37, etc.).
The service for which the rope is to be used determines the size, the
number and arrangement of wires, the number of strands, the lay, and
the type of core In a wire rope.
Classifications:
The most popular and most generally used constructions of wire rope are
six-strand ropes of these two classifications-the 6 x 19 and 6 x 37. The
6 x 19 classification contains a variety of constructions for wire rope,
ranging in number of wires per strand from 15 to 26.
Typical
constructions 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 and
constructions for wire rope with the number of wires per strand ranging
Mechanical Works
46
E & C Division
SHE Manual
In ropes with large diameters, 2 in. (6.4 cm) and larger, practically all
wire rope is produced in the 6 x 37 or 6 x 61 class. Therefore, because
of the large number of possible rope constructions that are available,
exercise care to make the proper selection
Service Requirements:
Mechanical Works
47
E & C Division
SHE Manual
The operating or design factors for rope used in hoisting are calculated
by dividing the nominal catalogue strength of the rope by the sum of the
maximum loads to be hoisted. It is normal practice to base this on static
loads. It is recommended that hoisting rope have at least the strength
of improved plow steel. For some applications, use extra-improved plow
steel, which is the greatest in strength, to provide an adequate design
factor and better service.
The minimum design factors for rope used in hoisting depend upon the
type of service required and the state codes covering the particular
hoisting operation. Many of these codes describe exactly how the design
and operating factors should be figured. Therefore, it is prudent to
check what codes are in force before making a final determination or
selection of wire ropes to be used in hoisting. Also obtain the advice of a
reliable wire rope manufacturer.
Causes of Deterioration:
Mechanical Works
48
E & C Division
SHE Manual
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 to
apply 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 and
harmful materials. Compressed air or steam jet, or other mechanical
method, cleans a rope effectively and thoroughly.
Chain Slings:
The safety of a chain sling assembly depends on the material used, its
strength for the load handled, method of attaching chain to fittings, and
proper inspection and maintenance. Alloy steel is the standard material
for chain slings because of its resistance to corrosion and wear and high
tensile strength. Hooks and attachments are generally made of the
same material,
Mechanical Works
49
E & C Division
SHE Manual
Synthetic web slings and metal mesh slings are also widely used in
industry. Synthetic web slings are useful for lifting loads that need their
surfaces protected; however, these slings are easily cut and have little
resistance to abrasion. As a result, these web slings require an initial
inspection, frequent on-the-job evaluation, and periodic formal
inspection by trained personnel.
Remove metal mesh slings from service if a broken weld or brazed joint is
discovered along the sling edge. Also watch for the following signs of wear.
Any one of these conditions or a combination of them, if ignored, could
eventually result in sling breakdown:
bent links
cracks in weld areas, in shoulders, or in any other section of link
kinks and gouges
Mechanical Works
50
E & C Division
SHE Manual
When inspecting the hook, measure between the shank and the narrowest
point of the hook opening. Whenever the throat opening exceeds 15% of
the normal opening, replace the hook. Pay special attention to slings to
which hooks have been added; make sure the hooks are secure.
Safe Practices
Follow these recognised safe practices to prevent chain failures:
51
E & C Division
SHE Manual
Slings having suitable characteristics for the type of load, hitch, and
environment shall be selected in accordance with appropriate
specifications.
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 or
support the load from the sides above the centre of gravity.
Slings should be long enough so that the rated load (rated capacity) is
adequate when the angle of the legs (branches) is taken into
consideration.
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
Mechanical Works
52
E & C Division
SHE Manual
Lifting gears:
Mechanical Works
53
E & C Division
SHE Manual
Sheaves:
The condition and contour of sheave grooves Is important for the service
life of wire rope. Periodically check sheave grooves (Figure 10-4), and
do not let them wear to a smaller diameter than those shown for used
grooves in Table 10-G. If they become worn more than this, expect a
reduction in the rope's service life. Reconditioned sheave grooves
should conform to the tolerance, shown in Table 10-G, for new (or re
machined) grooves.
On all new sheaves, the grooves should be made for the size of rope
specified. The bottom of the groove should have a 150-degree arc of
support, and the sides of the groove should be tangent to the ends of
the bottom arc. The depth of the groove should be one times the
nominal diameter of the rope. The radius of the arc should be one-half
the nominal rope diameter plus one-half the value.
Check sheaves for proper alignment when they are installed. During
rope changes, check the sheaves for worn bearings, broken flanges,
proper groove size, smoothness, and contour. Recondition or replace
heavily worn or damaged sheaves.
Sheave groove bearing pressures can become very hot depending upon
operating conditions and rope loading.
High pressures can cause
excessive sheave wear and shorten the life of wire rope. It is necessary,
therefore, to consider this factor and to select proper sheave materials
and liners at the time of installation. Information on this subject may be
found in most wire rope manufacturers' handbooks.
Mechanical Works
54
E & C Division
SHE Manual
Recommended
(times rope diameter)
Minimum
6x7
72
42
6x19
45
30
6x37
27
18
8X19
31
21
Drums:
Minimise crushing and excessive wear of wire rope using spirally grooved
drums with capacity for one layer rope. In any case, limit the number of
layers to three. Rope lifters at the flanges are recommended when two
or more layers are wound on drums. To distribute wear uniformly
crossover points, cut off one-and-a-quarter wraps every 6 months or
three or four times during the life of the rope. In no case should there be
fewer than two full wraps on a drum; three is preferred.
In general, avoid reverse bending of wire rope (bending first in one
direction and then in the opposite) over sheaves or drums. This wears
out 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 the
drum and a line perpendicular to the drum shaft and running through
the head or lead sheave.
To reduce any tendency for the rope to open-wind, do not let the fleet
angle exceed 1o30'. To assure the rope's starting back on the next
Mechanical Works
55
E & C Division
SHE Manual
layer, use a minimum angle of 0030 for smooth drums and 2o for
grooved drums. Adhering to these 'fications helps achieve uniform
winding on smooth-faced drums and also increases the winding
efficiency of grooved drums. For smooth-faced drums, proper direction
of lay of rope for specified winding conditions further helps achieve
uniform winding.
Installing a wire rope on a plain- or smooth-faced drum requires a great
deal of care. The starting position should be at the drum end so that
each turn of the rope winds tightly against the preceding turn. Maintain
close supervision during the entire installation process to make sure
that:
1. the rope is properly attached to the drum
2. appropriate tension on the rope is maintained as it is wound on the
drum
3. each turn is guided as close to the preceding turn as possible so that
there are no gaps between turns
4. there are at least two dead turns on the drum when the rope is, fully
unwound during normal operating cycles. Loose and uneven winding
on a plain- or smooth-faced drum, can, and usually does, create
excessive wear, crushing, and distortion of the rope. The results of
such abuse are lower operating performance and a loss in the rope's
effective strength. Also, on jobs that require moving and spotting a
load, the operator will encounter control difficulties because the rope
will pile up, pull into the pile, and fall from the pile to the drum
surface. The ensuing shock can break or otherwise damage the
rope.
Pulleys:
Mechanical Works
56
E & C Division
SHE Manual
Used
New
1/128
1/64
1/64
1/32
3/128
3/64
1/32
1/1 6
3/64
3/32
1/16
1/8
Mechanical Works
57
E & C Division
SHE Manual
Link tend to
close up
and
elongate
Bend
Stretched
Link
Twisted
Link
Wear
Bend
Cuts
Mechanical Works
Remaining Material
58
E & C Division
SHE Manual
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
Defective
Throat Open
Normal
Throat opening
more than 15% Hook should be
rejected
Defective
Hook worn out
Worn out
hook
Bent
Mechanical Works
59
E & C Division
SHE Manual
SHACKLES:
Inspect and discard if
Rope Fittings:
There are several ways to attach wire rope to fittings:
pressed fittings, mechanical sleeve splices, hand-tucked splices, clips and
clamps, 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 of
suitable size and design for ropes of different sizes.
The strength of an attachment is attained only when the connection is
made exactly according to the manufacturer's instructions.
Some types of attachments, such as pressed fittings or mechanical sleeve
splices that are used in making slings, must be made at either a wire rope
manufacturer's plant or at a properly equipped commercial sling shop.
Efficiencies of properly made hand-tucked splices vary according to the
splicer'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% when
IWRC-type wire rope is used.
Rope often is connected to the fittings of conveyances by means of clips
and clamps. They are rated to develop 75% to 80% of the rope's breaking
strength. It is important to retighten the nuts on all clips after the rope's
first load-carrying use, as well as at all subsequent regular inspection
periods.
Mechanical Works
60
E & C Division
SHE Manual
Socketing with zinc and a thermostate plastic resin will develop 100% of
the rope's breaking strength.
Since there is no ready way to detect flaws in the finished job, follow the
recommended procedure exactly.
In high-speed hoisting, fatigue is especially likely to develop with this type
of 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 unpredictable
efficiencies-40% or less. Using them is likely to result in the failure of a
rope assembly and under certai conditions to result in serious accident.
Inspection and Replacement:
The frequency of inspections and replacement of rope depends on service
conditions. Some plants and mines, for instance, make a daily inspection
for readily observable defects, such as kinking and loose wires, and a
thorough inspection weekly.
For the latter inspection, the rope speed is generally less than 60 feet per
minute (fpm).
The supervisor checks specifically for wear of the crown wires, kinking, high
strands, corrosion, loose wires, nicking, and lubrication. Rope callipers and
micrometers are used to determine changes in the cross section of rope at
various locations.
In most cases, sudden change in rope length and/or diameter is a warning
that the wire rope is nearing the end of its useful life and that it should be
removed from service. The reason for this change is general deterioration
of the structure of the interior rope, such as corrosion of uninspectable
wires and general deterioration of the core of wire rope. A decrease in the
rope's diameter, which may also occur, is difficult to determine in many
cases.
The number of broken wires per lay is one of the principal bases for judging
the condition of a rope.
If most of the broken wires in a lay are
concentrated in several strands, that section of the rope is weaker than it
Mechanical Works
61
E & C Division
SHE Manual
Mechanical Works
62
E & C Division
7.5
SHE Manual
Hoists
Material hoists and personnel hoists are made of tubular steel. Be
sure to consult with tubular steel manufacturers or suppliers for
current technical data. The plant supervisor or the contractor must
comply with the manufacturers specifications and limitations.
Hoists may be erected in hoistways inside the building or in outside
towers. Personnel hoists are used just for the transport of people.
Never permit personnel to ride on a material hoist. Do not permit
work in or on the hoistway while the hoist is in operation.
Post the rated load capacities, recommended operating speeds and
special hazard warnings or instructions on cars and platforms.
Inside Material Hoistways
If the material hoist is installed inside the building, enclose the
hoistway.
Solid enclosure is preferred. However, heavy wire
screening, -in. (1.25 cm) mesh, No 18 US gage wire, is often
substituted. 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-weight
gates and use latching or locking mechanisms.
Provide protective covering of heavy planking below the cathead of
all hoists. This will prevent objects from falling down the hoistway.
Outside Material Hoistways
Hoisting towers are usually made of tubular steel and are used on
construction sites. Base the design on a safety factor of at least
five. Erect the tower on a level and solid foundation, and have it
well guyed or fastened to the building.
Enclose the tower with heavy wire screening and equip it with a
fixed ladder extending the full height of the tower. Install standard
railings and toe-boards on runways connecting the tower to the
building.
Mechanical Works
63
E & C Division
SHE Manual
64
E & C Division
SHE Manual
65
E & C Division
with expanded metal.
substantial gates or bars.
SHE Manual
Protect
all
hoistway
entrances
with
66
E & C Division
SHE Manual
Mechanical Works
67
E & C Division
7.6
SHE Manual
Mechanical Works
68
E & C Division
SHE Manual
plant, the contractor and the plant's management should agree upon
the traffic flow. In that way, the areas in which the construction
equipment is to be operated will be known and isolated where
possible. The contractors key personnel and the plant's designated
personnel should receive drawings of these areas.
To avoid extra handling and vehicle movement, contractors should
be notified by the site officials about the exact location to make
deliveries.
Sometimes it may be necessary to transport employees in trucks
from one location to another within the work area. Unless this is
controlled, this operation can become a major source of serious
injuries.
In tractors and trailers, the coupling mechanism must be carefully
safeguarded and loads secured to the trailer. Motorised hand trucks
must be safeguarded
(1) to prevent the operator from being pinned between the truck
and a fixed object and
(2) to prevent the truck running up on the operator's heels.
Automated guided vehicles must have some means of stopping
should someone step in front of them. Such trucks should be
equipped with flexible bumpers that shut off power on contact.
Operators of industrial trucks can prevent accidents by using the
same safe driving techniques they employ on the highways. They
need to observe speed limits, exercise care in backing up, stop at
blind corners and doorways, keep trucks a safe distance apart, avoid
driving trucks into elevators unless authorised, and exercise caution
at railroad crossings.
Loading and unloading trailers require careful procedures to avoid
accidents. Operators should make sure the brakes are on, wheels
are blocked, loads are neatly stacked and stable, and the load is
fastened to the trailer securely.
Industrial trucks should not be used for any purpose other than the
one for which they were designed.
Mechanical Works
69
E & C Division
SHE Manual
Operators are responsible for the care of trucks and should never
leave a truck unattended, park in an aisle or doorway, idle engines
for too long, or ignore mechanical problems.
When driving, they should keep arms and legs inside the truck's
guard or operating station, keep passengers off the truck, and watch
out for pedestrians.
Industrial powered trucks should be inspected and overhauled
regularly.
Operators should inspect their trucks before and after each shift.
Repairs, replacements, or other work should be performed only by
trained mechanics wearing proper protective equipment, particularly
when handling electrically powered trucks. Repairs or re-fuelling of
gasoline and liquefied petroleum trucks should be done as per
norms/instructions to avoid health hazards and burns and
explosions. Only authorised fuel and fuel tank equipment should be
used on these trucks.
Operators must have a valid driver's license, good driving record,
and few, if any traffic violations. Contractors must carefully select
trainees to meet certain physical and mental qualifications required
by safety standards. Training programs should centre on company
policies, operating conditions, and types of trucks used.
Management should maintain records of each employee's driving
performance.
Secure all equipment being towed not only with a regular hitch or
drawbar but also with a safety chain attached to the pulling unit. A
drawbar failure can result in a serious accident.
When towing a scraper from one job to another, the operator should
use a scraper bowl safety latch, or place a safety bolt in the beam to
give maximum clearance for road projections such as at crossings.
This precaution prevents the bowl from striking the ground or
pavement and injuring persons or damaging equipment.
Mechanical Works
70
E & C Division
SHE Manual
Clearing work:
Work requiring exposure to low limbs of trees or to high brush
involves serious hazards. Suitable protective measures and safe
practices 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 also
should wear goggles to shield the eyes from whipping branches.
Head protection guards against injuries from falling branches. When
a bulldozer shoves hard against the butt of a large dead tree, the
tree may crack in the middle or limbs may fall onto the machine.
Dead branches or tops also can drop from live trees. A safe
procedure to eliminate the danger is to cut the roots on three sides
and then apply the power to the fourth side. Use a long rope to pull
over large trees, but make sure in advance that the tractor and
operator will be in the clear when the tree falls. Operators should
ensure that all workers in the area are out of harm's way before
pushing over any trees, bulldozing rock, and rolling logs.
Special hazards:
Fatalities can occur easily when equipment is used on dumps and
fills, near excavations, and on steep slopes. The operator should
keep the bulldozer blade close to the ground for balance when the
machine is travelling up a steep slope.
When a worker is driving a tractor-dozer down a slope, the person
should 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 way
down, the operator should not lower the blade to regain the load
because of the danger of overturning. Never use the blade as a
brake on a steep slope except in cases of extreme emergency.
Grounds conditions will determine how close to an excavation or the
crest of a dump and operator safely work a machine. Wet weather
means the operator must work at a greater distance from the edge
or crest. When the ground is treacherous, assign someone to signal
the driver.
Mechanical Works
71
E & C Division
SHE Manual
72
E & C Division
SHE Manual
Mechanical Works
73
E & C Division
SHE Manual
74
E & C Division
SHE Manual
Workers should not use solvents with flash points below 100 F (37.8
C) for cleaning equipment or parts.
When gasoline and other highly flammable fluids are used, transfer
them by approved pumps or store them in approved safety cans. Do
not store gasoline, fuel oil, and other flammable or combustible
liquids on equipment except in fuel tanks or approved safety cans.
Locate suitable fire extinguishers on, or close to, each industrial
truck.
Repairs:
Shut down all hazardous equipment for repairs.
Post suitable signs, and do not remove them until repairs have been
completed.
Move mobile equipment, if possible, to a safe location where
operations will not interfere with the repair work.
Block or crib equipment suspended in slings or supported by hoists
or jacks for repairs before anyone is permitted to work underneath
it.
For repairs on equipment made away from the source of power, such
as conveyors and cable ways, use chains, blocking, or similar
devices. Such precautions will prevent injury in case the equipment
is accidentally started.
Before repairs on electrically powered equipment are begun, lock the
main switch in the open (OFF) position. The person doing the
repairs should retain the key to the switch lock. If there is more
than one repairperson, each should lock the main switch with a
personal lock and retain the key.
Mechanical Works
75
E & C Division
SHE Manual
Mechanical Works
76
E & C Division
SHE Manual
Always inspect the forklift before you start work. ( mast for
broken weld, proper lubrication of roller tracks and chain, forks
properly placed/not cracked, hydraulic fluid level and leakage)
Mechanical Works
77
E & C Division
SHE Manual
Safety Tips:
Mechanical Works
78
E & C Division
8.1
SHE Manual
Critical Jobs
E & C Division
8.2.
SHE Manual
Confined Spaces:
If you are one of the workers who work in confined spaces each year, you
know 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 dangerous
air contaminants,
&
Which is not intended for continuous human occupancy.
Class A spaces are those that present situation which are immediately
dangerous to lift or health. These include spaces that are either deficient in
oxygen 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 protective
measures are not used.
Class C spaces are those where any hazards posed are so insignificant
that no special work practices or procedures are required.
Some examples of Confined Spaces
TANK
Critical Jobs
SILO
PIPELINE
E & C Division
SHE Manual
3.
Critical Jobs
E & C Division
SHE Manual
Critical Jobs
E & C Division
#
#
#
#
#
#
#
SHE Manual
Critical Jobs
E & C Division
SHE Manual
#
#
#
#
#
#
#
Critical Jobs
E & C Division
SHE Manual
Minimum general ventilation rate of 2000 cubic feet per minute per
welder be maintained in confined spaces.
Critical Jobs
E & C Division
#
#
#
#
SHE Manual
If local exhaust is used, the capture velocity at the point of work must
be 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 - or
mercury -coated base metals.
Welding machines and compressed gas cylinders must be kept outside
the confined spaces.
When work stops for a prolonged period of time, electrodes must be
removed from their holders and gas flow to torches must be shut off
from outside the space.
Critical Jobs
E & C Division
SHE Manual
Critical Jobs
E & C Division
SHE Manual
OR
If make-up air is inadequate, Carbon monoxide produced by inefficient
combustion, which combines with hemoglobin about 200 times more
easily than oxygen.
Oxygen Enriched Atmosphere
#
#
Permit flammable gases and vapors to ignite over a much wider range
of concentrations than is possible in ordinary air.
Alters the burning characteristics of many materials, making them
both 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.
Critical Jobs
10
E & C Division
9.
SHE Manual
Introduction:
The purpose of welding is to join metal parts. All welding process requires
heat and sometimes other substances to produce the weld. Because high
heat is used to make the weld, a number of by-products results from the
process, including fumes and gases that can be a serious health hazard to
workers. Safety hazards are also associated with welding, such as the
potential for fire or explosion and injuries form arc radiation, electrical
shock, or material handling.
Definitions used in this chapter are those of the American Welding
Society. Welder and Welder Operator refer to the individual only. The
machine performing the welding operation is referred to as the Welding
machine. Equipment supplying current for electric welding is called either
a Welding generator or a Welding transformer.
Hazards:
1. Health Hazards:
The most significant health hazard in the welding process is the
generation of fumes and gases. The amount and type of fumes
and gases involved will depend on the welding process; the base
material, the filler material, and the shielding gas, if any. The
toxicity of the contaminants depends primarily upon their
concentrations, and upon the physiological responses of the
human body. Sampling by an industrial hygienist or other
qualified person may be necessary to fully identify the fumes and
gases actually being given off in a specific operation.
(a) Toxic Gases:
Exposure to various toxic gases generated during welding may
produce one or more of the following effects:
Chronic bronchitis
Welding and Gas Cutting
E & C Division
SHE Manual
Asphyxiation
The major toxic gases associated with welding are classified as
primary pulmonary and nonpulmonary.
(b) Cleaning Compounds used
Because of their chemical properties, cleaning compounds can
create health hazards if improperly mixed. They often require
special ventilation precautions. Follow the manufacturer's
instructions.
(c) Chlorinated Hydrocarbons
Degreasing operations often employ chlorinated solvents that can
decompose to toxic phosgene gas in the presence of the
ultraviolet radiation emitted by the welding arc.
(d) Asbestos
If welding or cutting involves asbestos, the regulations of the
agency having authority must be consulted before beginning the
job. Asbestos can produce fibrosis and lung and other cancers.
2. Safety Hazards
(a) Fire Protection
Because portable welding and cutting equipment creates special
fire hazards, it should be used in a permanent welding and
cutting location that can be designed to provide maximum safety
and fire protection. Otherwise, the welding and cutting site
should be inspected to determine what fire protection equipment
is necessary.
It is advisable, particularly in hazardous locations, to require "Hot
work" permits issued by the welding supervisor, a member of the
plant fire department, or some other qualified person before
welding or cutting operations are started. Specifications for hot
work permits are outlined in the annexe.
(b) Floors and Combustible Materials
Where welding or cutting must be done near combustible
materials, special precautions are necessary to prevent sparks or
Welding and Gas Cutting
E & C Division
SHE Manual
hot slag from reaching such material and starting fires. If the
work itself cannot be moved, the exposed combustible material
should, if possible, be moved a safe distance away. Otherwise, it
should be covered with sheet metal. Spray booths and ducts
should be cleaned to remove combustible deposits.
Before
welding or cutting is started, wood floors should be swept clean
and, preferably, covered with metal or other non-combustible
material where sparks or hot metal may fall. In some cases, it is
advisable to wet down the floor, though the wet floor increases
the shock hazard to electric (arc and resistance) welders and
necessitates special protection for them.
If gas welding or oxygen cutting is done inside a booth provided
for arc welding, the gas cylinders should be placed in an upright
and secured position away from sparks to prevent contact with
the flame or heat.
Hot metal or slag should not be allowed to fall through cracks in
the floor or other openings, nor into machine tool pits. Cracks or
holes in walls open doorways, and open or broken windows
should be covered with sheet metal guards. Because hot slag
may roll along the floor, it is important that no openings exist
between the curtain and the floor. Similar protection should be
installed for wall openings through which hot metal or slag may
enter when welding or cutting operations are conducted on the
outside of the building.
If it is necessary to weld or cut close to wood construction, or
near combustible material that cannot be removed or protected,
a fire hose, water pump tank extinguisher, or fire pails should be
conveniently located.
Portable extinguishers for specific
protection against Class B and C fires should also be provided.
Pails of limestone dust or sand may be useful. It is good practice
to provide a fire extinguisher, either dry chemical, multipurpose
chemical, or carbon dioxide, for each welder.
A fire watcher equipped with a suitable fire extinguisher should
be stationed at or near welding or cutting operations conducted in
hazardous locations to see that sparks do not lodge in floor
cracks or pass through floor or wall openings. The fire watch
Welding and Gas Cutting
E & C Division
SHE Manual
E & C Division
SHE Manual
6. Remove the drums from the steaming rack, and fill drum part way
with caustic soda or soda ash solution.
The drums for at least 5
minutes. Light hammering with a wood mallet will help to loosen
scale.
7. Thoroughly flush the drums for at least 5 minutes boiling water. A
water spray nozzle placed 6 to 8 in to 20 cm) inside the drum can be
used. 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 is
listed 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 a
combustible gas indicator. Test for toxic contaminants and for oxygen
sufficiency or enrichment if personnel are to enter.
12. Make similar tests just before welding repair operations are
performed. If operations extend over an appreciable period of time,
make repeated tests.
Precautions for employee protection during container cleaning operations
include the following suggestions:
Wear head and eye protection, rubber gloves, boots, and aprons
when handling steam, hot water, and caustic solutions. When
handling dry caustic soda or soda ash, wear approved respiratory
protective equipment, long sleeves, and gloves.
To handle hot drums, wear suitable hand pads or gloves. Steam
irons or other hot surfaces that may be touched should be insulated
or otherwise guarded.
Dispose of residue in a safe manner. In each instance, the method
of disposal should be checked for hazards.
If a vessel must be entered, wear respiratory protective equipment
approved for the exposure and a safety harness with attached
lifeline tended by a helper who is similarly equipped and stationed
outside the vessel. Rescue procedures should be tested for
adequacy before beginning.
Refer to Material Safety Data Sheets provided by the manufacturer to
identify any of the materials listed above that may be contained in the
consumable.
Whenever these materials are encountered as
Welding and Gas Cutting
E & C Division
SHE Manual
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 provide
protection from welding radiation; nor does the welding space
contain partitions, balconies, or other structural barriers that
obstruct cross-ventilation m materials covered above are not
present as deliberate constituents.
E & C Division
SHE Manual
velocity of 100 ft per min (30 m per min), and be maintained for a
distance 'Of approximately 2'ft (0.6 m) directly above the work area.
Precautions must be taken to ensure that contaminants are not
dispersed to other work areas.
General area mechanical ventilation includes roof exhaust fans, wall
exhaust fans, and similar large area air movers. General mechanical
ventilation is not usually satisfactory. It is often helpful, however, when
used in addition to local ventilation. General mechanical ventilation may
be necessary ventilation to maintain the general background level of
airborne contaminants below the levels referred to or to prevent the
accumulation of explosive gas mixtures.
E & C Division
SHE Manual
E & C Division
SHE Manual
13. Cylinders together with their valves and other fittings and other
fittings and the identification colours under these rules shall always
be maintained in good condition.
14. No oil similar lubricant shall be used on any valves or other fittings of
any cylinder.
15. Every cylinder containing compressed gas shall have valve securely
closed so as to prevent leakage.
16. If a leak in the valve can not be rectified by lightening the gland nut
or the spindle, the cylinder shall be removed to an open space where
it is least dangerous to life and properly and the filler shall be
informed.
17. As per rule 9 (2) of gas cylinder rules,1981.
Rule 9(2) of gas cylinder rules, 1981 prescribes 4 warning in the following
terms are attached to every cylinder containing permanent or liquefiable
gas, 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 easy
identification. To prevent inter change of fittings, the valve out lines are
screwed left and right respectively.
Welding and Gas Cutting
E & C Division
SHE Manual
10
E & C Division
SHE Manual
13. For storage of gas cylinders flammable storage rooms for cylinders
containing flammable gases should be well ventilated to prevent the
accumulation of explosive concentrations of gas.
14. Never allow cylinders to come into contact with electrical apparatus
or live wires, since arcing may be set up which will heat or damage
the cylinders.
15. Never strike an arc or tap an electrode on a gas cylinder whether full
or empty.
16. Oil or grease must under no circumstances be allowed to come in
contact with one another.
17. Never transport cylinders with the regulators and hose attached
unless a proper trolley or carrier is used. When transporting by a
trolley the cylinder valve must be shut before the cylinder is moved
from place to place.
18. If an acetylene cylinder becomes hot or fires internally due to
external fire or uses of faulty equipment, close the valve, disconnect
the regulator (if possible) remove the cylinder into the open, the
open the valve fully to allow the gas to escape freely. Meantime,
apply water to cylinder body from a hose or immerse the cylinder in
a 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 the
valve seat. Care should be taken to see that the regulator chosen be
the correct one to use for the gas contained in the cylinder.
2. Before fixing a regulator on to a full cylinder, always release the
adjusting screw for regulating the pressure output, otherwise there is
a risk of damage to the regulator.
3. Make sure that the threads on regulators and other auxiliary
equipment are the same as those on the cylinder valve outlets.
Welding and Gas Cutting
11
E & C Division
SHE Manual
12
E & C Division
13.
SHE Manual
14. Open the cylinder valve slightly to let the hand on the high pressure
gauges move up slowly. On an oxygen cylinder gradually open the
cylinder 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 be
isolated from supply main, if necessary.
2. Both portable and stationary equipment must be double earth with 8
SWGI wire. In addition, the work must, of course, be earthed.
3. On the output (i.e. Secondary) side of transformer, cables of the
correct type and capacity tied with the appropriate connectors / lugs.
4. In service, the welding operator should check all external connections
daily and report any weakness, defects etc.
5. Ensure that all connections are clean and tight, that they are correctly
made, 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 prevent
overheating.
7. Much of the heat generated in a holder is the result of poor electrical
contact at the jaws holding the electrode, and a spring or other grips
ensures a uniform pressure. Use good quality insulated electrode
holder.
13
E & C Division
SHE Manual
2.
3.
4.
5.
(B) Gloves
To protect the hands against heat, spatter and radiation, gloves must
be worn, and these should be of the leather gauntlet type with
canvas or leather cuffs, as specified in IS :
(C) Head protection
* When molten metal or hot particles are emitted during welding, the
welder 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 into
the boots or shoes.
14
E & C Division
SHE Manual
15
E & C Division
SHE Manual
16
E & C Division
SHE Manual
17
E & C Division
SHE Manual
ANNEXURE
GAS CUTTING & WELDING
CHECK LIST
Sr.
No.
Description
Observation
Yes / No
1.
2.
3.
4.
5.
6.
7.
8.
9.
Action /
Comments
18
E & C Division
SHE Manual
13. Are clamps and clips are used only for tying
up of welding hoses?
14. Is welding torch conforms to BIS
specification & nozzle is free from scale?
15. Is tip of welding torch nozzle is free from
scales?
16. Are colour code marking for flammable gas
cylinder and oxygen cylinder is done?
17. Are pressure gauges are provided & are in
working condition?
18. Are electrode holder used, conforms to BIS
specification?
19. Is current carrying capacity of electrode
holder is adequate?
20. Is physical condition of connecting lead is
O.K.?
21. Is crimping of lugs on welding lead O.K.?
22. Are gas cylinder kept vertically at safe
places?
23. Are hazardous (combustible)materials kept
beside / below gas cutting operation?
24. Are fire extinguishers / fire buckets
available near work place?
25. Are empty & filled cylinders stored
separately away from heat / sun light?
19
E & C Division
SHE Manual
20
E & C Division
10
10.1
Work Environment:
SHE Manual
E & C Division
SHE Manual
Check that exhaust outlets are fitted with silencers or mufflers, and do
not 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 is
sited behind earth mounds or brick stacks to isolate or screen it as far
as possible.
10.1.1.2
Hearing protection:
10.1.1.3
Vibration:
E & C Division
SHE Manual
10.1.2 Illumination:
THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION OF
EMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES, 1998
under Rules 50 & 124 provides statutory illumination requirements for
passages and for excavation sites. The general requirements are given
below.
All parts of the site need to be properly lit by natural or artificial means
whenever work is going on. Site lighting is always necessary in those
areas short of natural light such as shafts and enclosed stairways.
Artificial lighting should be placed to avoid deep shadows - these may
conceal hazards which would be obvious in good light. Mounting of lights
should be as high as practicable to avoid glare, and lights should be
placed so that workers do not have to work in their own shadow.
Only robustly installed fittings which are well out of reach, such as
floodlighting, should be used and operated at full mains voltage.
Temporary electric lighting should be installed by trained electricians
using low-voltage equipment.
Ensure that the following are followed by workers:
Make sure that cables are fastened well off the ground and do not let
cables or connections trail in wet conditions.
10.1.3
Ventilation:
E & C Division
SHE Manual
10.1.3.3
Cold weather:
E & C Division
SHE Manual
Workers repeatedly using vibratory tools such as rock drills may suffer
"white finger" syndrome involving sensory loss as a consequence of
cold.
Wind can affect temperature. When the air temperature is 100 Celsius
and the wind speed is 32 km per hour, the temperature, so far as the
body 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.
Choose clothing which allows moisture to escape but does not allow
wind and rain to penetrate: waterproof clothing tends to prevent
evaporation of moisture.
E & C Division
SHE Manual
Annexure -1
SCHEDULE-VI
PERMISSIBLE EXPOSURE IN CASES OF CONTINUOUS NOISE
(See rule 34)
Pressure
95
97
100
102
105
107
110
115
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
and asbestos substitutes, aluminized clothing, flame resistant or flameretardant materials, aprons kneepads, gloves and gauntlets, hand
leathers and arm protectors, imperious materials, heat-stress and cold
weather clothing, and conductive or nonconductive clothing.
Specification for safety equipment is given in annexure 1. In each
technical chapter of part II, whoever required specific personal protective
equipment requirements is dealt with.
10
E & C Division
SHE Manual
Annexure 1
SAFETY HELMET
Fibre glass HDP etc should weigh 400 to 450 gms and be
moisture shock and fire resistant. It should withstand 20 deg
and plus 50 deg. C. If a plumb bob of 500 gms weight with
conical steel point is dropped from a height of 3M there should
be no piercing or denting.
SAFETY BELT
General purpose harness safety belt consists of one body belt
and two shoulder straps made from strong closely woven
approximately 50 mm wide 6 ply cotton webbing with 3 mm
long 12 mm dia tested quality polypropylene rope. All iron
fittings be galvanised and jointless cut from solid. A special Dring to be provided at the back of safety belt and life line is
directly spliced (minimum 9) from back of D-ring.
GOGGLES
(a)
(b)
(c)
11
E & C Division
SHE Manual
GLOVES
(a)
(b)
(c)
DUST MASK
Cloth dust mask flannel type made from netting cloth outside and
fine canvas cloth inside sandwiched with 3 mm foam padding,
enclosing the mouth and the nose, with elastic head strap ensuring
safe breathing in dusty atmosphere.
SAFETY NET
6 mm dia with twin rope inside for 50 mm x 50 mm meshing with
provision for intermediate rope of 12 mm dia every 1M and 20 mm
dia rope on all four sides, with provision for tying the net at every
one meter.
All ropes should be made of tested quality
polypropylene rope. There should not be any joint in the mesh.
12
E & C Division
SHE Manual
EAR MASK
When noise level exceeds 85 to 90 decibels, ear muffs / earplugs
are to be used.
13
E & C Division
SHE Manual
Duration of training.
Frequency to training.
Responsibility and arrangement of first aid training.
Maintenance of records.
Placement of first aid boxes.
Contents of first-aid box.
Minimum No. of trained first aiders.
E & C Division
SHE Manual
2.
RCM/RCE shall check and sign all registers pertains to first aid once
in every fifteen days.
3.
E & C Division
SHE Manual
Annexure - I
Contents of First Aid Box
The first aid shall be distinctively marked with a red cross on a while
background and contain following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Medicines
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
E & C Division
28. Tabs Placidox (2 mg )
29. Tabs Colinol P/ Spasmoproxyvon
Nos.)
30. Tabs Rantidine (200 Nos.)
31. Gentycin Eye / Ear drops (10 Bottles)
day
32. Tabs Theo-asthaline (100 Nos.)
33. Electral Powder - Small Pack (100 Nos.)
SHE Manual
1 Tab SOS
1 Tab 3 times a day (200
1 Tab 2 times a day
2/3 drops, 2/3 times a
1Tab 2/3 times a day
For gassing
E & C Division
SHE Manual
Annexure - II
INSTRUCTIONS
FOR FEVER / COLD
CAPS.
TABS.
TABS.
CAPS.
TABS.
AMOXICILINE +
NEOFARBRIN OR
CROCIN.
AMOXICILINE +
IBUGESIC
TABS. CROCIN
FOR SORETHROAT
TABS.ALTHROCIN+CROCIN
FOR BRONCHITIS
FOR DYSENTRY
TABS. COLINOL P
TABS. IBUGESIC
POLARAMINE
TABS PALCIDOX 2
TABS THEO-ASTHALINE
MULTIGESIC CREAM
E & C Division
SHE Manual
OINTMENT THROMBOPHOB
E & C Division
SHE Manual
Annexure - III
Sr.
No.
Name of patient
Date
Sex &
Age
Type of
Injury
Part of
body
injured
Type of
Treatment
given
E & C Division
12.
SHE Manual
Electrical Safety
General :
Electrical Injuries:
Current flow and time are the factors that cause injuries in electrical
shock. The severity of electrical shock is determined 1) by the amount of
current that flows though the victim (Table 1), 2) by the length of time
that the body receives the current and 3) the part of body involved.
But current flow depends on voltage and resistance, these factors are
also important and if it is alternating current frequency. Heat is a
secondary effect on the body. Such current flow can easily be received on
contact with low voltage sources of the secondary lighting or power
circuit.
A persons main resistance to current flow is the skins surface. Dry skin
has a fairly high resistance. A sharp decease in resistance takes place
when the skin is moist (Table 2). Once the skins resistance is broken
down, the current flows readily through the blood and the bodys tissues.
The resistance decreases rapidly with increase in voltage. Low voltage is
dangerous as it prevents the victim from breaking the contact with the
circuit.
Internal Injuries:
Death or injuries from electrical shock may result from the following
effects 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 asphyxiation
when the contact is prolonged.
2.
Temporary paralysis of the nerve center, which may result in failure
to breath, a condition that often continues long after the victim is
freed from the circuit.
3.
Interface with the normal rhythm of the heart, causing ventricular
fibrillation. In this condition, the fibers of the heart muscle, instead
of contracting in a coordinated manner contract separately and at
different times. Blood circulation ceases and unless proper
resuscitation efforts are made, death occurs. The heart cannot
__________________________________________________________
Electrical safety
1
E & C Division
4.
5.
6.
SHE Manual
E & C Division
SHE Manual
__________________________________________________________
Electrical safety
3
E & C Division
SHE Manual
At the design and planning stage, and as the project develops, issues
which need to be considered or reviewed will include the following:
! Giving intimation to the state authorities for providing power
supply 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 of
metering equipment and switchgear, distribution boards and
supply cables.
! The way in which the system will be modified /extended as the
work progresses.
! Operation of temporary system and the use of plant and
equipment 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.
__________________________________________________________
Electrical safety
4
E & C Division
SHE Manual
Staff Appointments:
Before starting work the principal or main contractor/s should appoint
key personnel responsible for electrical installation. Their competency
is based on their training and experience, knowledge of the risks
involved in their job and the ability to complete them safely.
Electrical Equipment Locations
1. The entrances to enclosures containing exposed high voltage
energised parts, such as transformer switch yards, generator
line and neutral cabinets or rear entry motor control centers,
shell be kept locked. Access doors or gates to rooms, vaults or
fenced enclosures containing electrical equipment shell be
readily opened from the inside without the use of a key.
2. Permanent and conspicuous warning signs shell be posted on all
doors or gates that provide access to enclosures containing
exposed energised parts and conductors forbidding unqualified
persons to enter. Such signs shall be legible at 12 feet, of
sufficient durability to withstand the environment involved, and
shall read substantially as follows:
WARNING HIGH VOLTAGE KEEP OUT
Some typical site situations along with the precautions to be
taken are given below:
Generators:
A supply from electrical board is not always available. In these instances
the 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 expert
advice may be needed particularly on earthing.
For small-scale work, or in locations remote from the site supply, portable
generator (with outputs of up to 10kVA) are often used. For short time
work (e.g. less than one day), these generators need not be earthed
provided that they are only used with ClassII (double insulated or all
insulated) tools or equipment.
__________________________________________________________
Electrical safety
5
E & C Division
SHE Manual
The smaller, single phase generators used for 110V supplies, (i.e. those
with ratings up to about 5kVA) need not be earthed, if all the equipment
in use is double insulated, or if it is supplies only one item of earthed
equipment. However, the equipment should be bonded with the frame of
the generator. (Bonding involves connecting items of metalwork together
in 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), the
generating set may be either single or 3 phase. Particular care is needed
to ensure that the system is installed safely and this may require
specialist advice. Matter to consider include the following:
" Generator needed to be earthed, by bonding the neutral to the
frame and connecting the frame to earth;
" The impedance of the bonding needs to be low enough to ensure
correct operation of protective devices (fuses, circuit breakers
etc.)
" Sensitive earth fault protection may be necessary if earthing
conditions are difficult.
Further guidance on earthing and bonding of generator system are given
under appropriate headings.
Generator should be connected and operated so that they are separate
from the public supply system unless agreement has already been
obtained 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 effective
rests with the person in charge of the site, not with the electricity
supplier.
"
__________________________________________________________
Electrical safety
6
E & C Division
SHE Manual
"
"
"
"
__________________________________________________________
Electrical safety
7
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
" Plant such as lifts and hoists, which may be relocated occasionally
during the work, is recommended to be supplied by armour cable.
If, in the course of the construction operations, the plant is to be
relocated, a safe method of work must be adopted. This will include
turning off the supply and disconnecting the cable before the plant
and cables are moved. Plant which is moved frequently (e.g. a
cement mixer) should be connected to the supply by a flexible cable
with protective braid and abrasion-resistant sheath. Cables will need
to be suitably located and adequately protected so that they will not
be damaged.
" If equipment has a high current requirement (current ratings greater
than 16 amps), arcing can occur if the plug and socket are
separated under load, causing burn or other injuries. Ways of
isolating the supply should be provided to ensure that the supply is
switched 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 and
plugs are still vulnerable to damage and should be regularly
checked. It is essential that the type of equipment selected is
suitable for use on a construction site, and that any restrictions on
use 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 themselves
eliminate or reduce the risks by selecting cordless tools or tools,
which operate, from a reduced low voltage supply, (e.g. 110V
systems which are center tapped to earth). For lighting, lower
voltages can be used and are even safer.
" There have been fatal accidents where 110V equipment fitted with plugs
designed for a 230V system or damaged.110V plugs have been
plugged into 230V supplies. To avoid danger, plugs and sockets
used on the reduced low voltage system should not be
interchangeable with 230V (mains) plugs and sockets. These
industrial plugs and sockets are more robust than domestic type
equipment, which is not designed for use on construction sites.
__________________________________________________________
Electrical safety
10
E & C Division
SHE Manual
" Cables with solid conductors (non-stranded) are designed for use in
fixed installations. The conductors inside are brittle and liable to
break if bent, so they should not be used as either extension leads
or replacement cables for portable equipment.
Use of main voltage equipment:
" When main voltage equipment is used on construction sites, the risk of
injury or death arising from the use of damaged or faulty
equipment, leads or plugs is unacceptably high unless special
precautions are taken. The precautions must reduce the risk to an
acceptable level taking into account the constraints regarding RCDs
mentioned in following paragraphs. Reasonably practicable
precautions include:
(a)
(b)
__________________________________________________________
Electrical safety
11
E & C Division
"
"
SHE Manual
(c)
Selecting tools that are designed for trade and work use.
Double insulated equipment is strongly recommended where it
is necessary to use a main voltage supply, because the tools
themselves are less likely to give rise to danger. (Danger can
still arise, however, if the cables, plugs or equipment casing
are damaged). Any restrictions on use out in the
manufacturers instructions should be observed.
(d)
__________________________________________________________
Electrical safety
12
E & C Division
SHE Manual
E & C Division
"
"
"
SHE Manual
__________________________________________________________
Electrical safety
14
E & C Division
SHE Manual
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 is
generated while charging a battery.
" Never use water on an electrical fire.
" Never look directly at open switches or breakers when energising or deenergising 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)
(b)
(c)
" Never pull any fuse that is carrying current. Never break a circuit under
load, severe arcing may occur.
" Use approved tools and hot circuit handling equipment when working
on energized equipment. Be thoroughly familiar with the circuit to
be worked on.
" Personnel should be stationed near the main switch or circuit breaker so
that the equipment can be de-energized immediately in an
emergency.
__________________________________________________________
Electrical safety
15
E & C Division
SHE Manual
" Metal ladders and scaffolds are electric conductors, they should never be
used around electric circuits or in place where they can come in
contact with electrical circuits.
" Extension cords should not be tied to electric outlets. These cords must
be free so they can be unplugged in an emergency.
" Use hand line when raising or lowering tools. Never lower electrical tools
by the cord.
" Cable trays are not designed to support loads, to be walked on, or used
to secure safety belt lanyards.
" Always de-energize circuits before attempting to reset them.
" Follow the following safe work practices:
Table1 - Safe work Practices
Voltage
Remove
Jewelry
(Y/N)
Insulated
tools
(Y/N)
Rubber
Gloves
(Y/N)
Eye
Protection
(Y/N)
Rubber
Matting
(Y/N)
Safety
Signs
(Y/N)
0-150
151-300
301-600
>600 (*)
Safe
Distance
(Table
2/3)
Line (a)
Table 2
Line (b)
Table 2
Line (b)
Table 2
Table 3
__________________________________________________________
Electrical safety
16
E & C Division
SHE Manual
Annexure - II
Working Clearance (Safe Distance):
The dimension of the working space in the direction of live parts
operating at 600 volts or less and likely to require examination,
adjustment, servicing, or maintenance while energized shall not be less
than indicated in Table 2 and less than indicated in Table 3 for live parts
operating at greater than 600 volts. Distances shall be measured from
the live parts if such are exposed, or from the enclosure front opening if
such are enclosed.
Table 2 working Clearances (less than 600 volts)
Nominal Voltage to
Ground
0-150
151-600
Minimum Clear
(I)
(ft)
3
3
Distance for
(II)
(ft)
3
3.5
Condition
(III)
(ft)
3
4
Minimum clear
(I)
(ft)
3
4
5
6
8
Distance for
(II)
(ft)
4
5
6
8
10
Condition
(III)
(ft)
5
6
9
10
12
Where for both Tables 2 and 3 conditions (I), (II), and (III) are as
follows:
(I)
Exposed live parts on one side and no live or grounded parts on the
other side of the working space, or exposed live parts on both sides
effectively guarded by suitable wood or other insulating materials.
Insulated wire or insulated busbars operating at not over 300 volts
shall 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 considered
grounded surface).
__________________________________________________________
Electrical safety
17
E & C Division
SHE Manual
(III) Exposed live parts on both sides of the workspace (not guarded as
provided in condition (I)) with the operator between.
NOTE
HEADROOM:
__________________________________________________________
Electrical safety
18
E & C Division
SHE Manual
Annexure - III
Overhead Lines:
When work is performed in locations containing energized overhead lines
which are not guarded, isolated, or insulated, precautions shall be taken
to prevent employees form contacting such lines directly (through the
body) or indirectly (through conductive tools or equipment, i.e. ladders).
When work near overhead lines is required, minimum distance shall be
maintained to those lines in accordance with following table.
Nominal Voltage to Ground
Minimum Distance
50KV or below
10 ft.
50KV or above
10ft. + **
__________________________________________________________
Electrical safety
19
E & C Division
SHE Manual
Annexure IV
__________________________________________________________
Electrical safety
20
E & C Division
13.
SHE Manual
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 without
damaging the parts being tested. Nondestructive testing methods locate
the following defects:
13.1 Radiography
Radiography uses x-ray and gamma rays. X-rays are unidirectional and
their wavelengths can be varied, within certain limits, to suit the
E & C Division
SHE Manual
Isotopes
Radioisotopes commonly used in industrial radiography are Cobalt-60
and Iridium-192, which are artificially produced by bombarding with an
excess of neutron, 192 & 60 represent mass number (atomic weight) of
the isotopes.
E & C Division
SHE Manual
E & C Division
SHE Manual
Permissible limit:
Organ or
Tissue
Whole body Red
bone marrow
& On hands.
In a
lifetime
300
mSv
In a year
In a week
50 mSv
In a
quarter
30mSv
Skin or bone
Tissue & thyroid
300 mSv
150 mSv
Extremities
750 mSv
150 mSv
Any other
organs, Lens of
eyes
150 mSv
80 mSv
1mSv
E & C Division
SHE Manual
Time:
The radiation dose received by person depends on the total time spent
by 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 and
exposed to 10mR, another operator who takes 2 minutes to do the
same 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 most
economical and effective method of reducing the radiation hazard is to
increase the radiation distance between the radiation source & person.
The radiation intensity or radiation level from a given source decreases
as we move away from the source it is governed by the inverse square
law.
Shielding:
Shielding is the absorbing material is provided in order to reduce the
radiation intensity to the required value. The shielding properties of any
material depend on its atomic number and energy of the incident
radiation. Most commonly used shielding material is lead.
E & C Division
SHE Manual
2.
3.
4.
5.
6.
7.
8.
Ensure that all walls, floors, ceiling & doors is having sufficient
shielding so as to minimise radiation level below the
recommended limit.
9.
2.
Lock the camera to ensure that the source assembly would not be
released.
E & C Division
3.
SHE Manual
2.
3.
4.
5.
6.
7.
E & C Division
SHE Manual
8.
9.
10.
The operator should be aware of the dose record and send the
records for periodic medical examination.
11.
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
Spray Painting
Hazards
Painting and paint removal present hazards requiring effective controls.
Hazards include exposure to toxic materials and flammable or explosive
mists, particulates, and vapors.
Inhalation of mists and vapors from nearly all paints, solvents, thinners,
cleaning chemicals, strippers, and epoxies can be injurious depending
upon the agent's toxic characteristics and the amount and method of
exposure.
Further, many paints can physically injure the skin and eyes, or be
absorbed through the skin. Potential physical and health hazards can be
effectively controlled by appropriate work procedures, controls, facility
design, protective clothing, and equipment.
Safety
1. Pressure Equipment
Pressure equipment used in painting operations is hazardous because of
the compressed air component; therefore, the supervisor should ensure
that spray painting equipment is in serviceable condition. On all air-type
spraying equipment a pressure regulator valve shall be installed in the air
line between the compressor and painting equipment. A pressure relief
valve and a pressure gauge shall be installed between the pressure
regulator and pressurized paint containers and/or spray guns. Pressure
relief valves shall be set to open at pressures not more than 10 pounds
above the required working pressure.
2. Other Equipment
Painter's ladders, scaffolds, and other equipment shall be inspected prior
to use to be certain they are in safe condition.
3. Paint Mixing
Paint mixing shall be done in designated, adequately ventilated rooms
constructed of fire-resistant materials. All sources of ignition shall be
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
15.
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
Air powered tools include air hoses, grinders and pneumatic impact
tools. To prevent injuries associated with air hoses, workers should
make sure hoses do not present tripping hazards, avoid using
hoses as cleaners and prevent accidental disconnection of hoses
from the tools. Air-powered grinders require the same type of
guarding as electrical grinders.
E & C Division
SHE Manual
Some does and donts using power tools are listed in Annexure 2.
E & C Division
SHE Manual
Annexure 1
PORTABLE
ELECTRIC
TOOLS
Inspection Checklist
GENERAL
Low voltage or battery powered equipment used in
tanks and wet areas?
Tools well maintained?
Motor in good condition?
Approved tools used in explosive atmospheres?
Tools left where they cannot fall?
Yes
Yes
Yes
Yes
Yes
/No
/No
/No
/No
/No
CORDS
Insulation and plugs unbroken?
Cords protected against trucks and oil?
Cords not in aisles?
Yes /No
Yes /No
Yes /No
GROUNDING
Ground wire fastener in safe condition?
3-wire plug extension cord (if a 3-wire tool)?
Ground wire used?
Defects or minor shocks reported?
Ground fault circuit interrupter used?
Yes
Yes
Yes
Yes
Yes
/No
/No
/No
/No
/No
GUARDING
Guards used on grinders and saws?
Movable guards operate freely?
Eye or face protection worn?
Yes /No
Yes /No
Yes /No
E & C Division
SHE Manual
Annexure - 2
Familiarity Breeds
Injuries
E & C Division
SHE Manual
3.
4.
5.
6.
7.
8.
A.
1.
2.
3.
4.
5.
6.
E & C Division
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
B.
Power tools:
1.
2.
SHE Manual
E & C Division
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
SHE Manual
E & C Division
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
SHE Manual
10
E & C Division
SHE Manual
Annexure 3
Personal
Protective
Equipment
Workers using revolving tools such as drills saws and grinders should not
wear ties, gloves loose clothing and jewelry. Clothing should be free of
oil, solvents or frayed edges to minimize the fire hazard from sparks.
The weight of most power tools makes i9t advisable for users to wear
safety shoes to reduce the chances of injuries should the tools or workpiece fall or be dropped.
When power tools are used in overhead places, the operator should wear
fall-protection devices to minimize the danger of falling, should be tool
break 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 below
should it be dropped.
On buffing, grinding and sanding jobs that produce harmful dusts provide
workers with approved dust-type respirators. For operators of powderactuated tools or hammers, provide hearing protection if more positive no
controls are possible.
In all operations where striking and struck tools are use or where the
cutting action of tool causes particles to the provide eye protection that
conforms to ANSI Z87.1 Practice for Occupational and Educational Eye
and False Protection. Minimize the hard of flying particles by using
nonferrous, soft striking tools and shielding the job site with metal, wood
or canvas. However, eye protection still required.
Wear eye protection or face shields when using wood working or cutting
tools such as chisels, brace and bits planes scrapers and saws. There is
always the chance of particles falling or flying into the eyes. Also wear
eye protection or face shields when working with grinders buffing wheels
and scratch brushes. The unusual positions in which the wheel operates
may cause particles to be thrown off in all directions. For this reason,
eye protection is even more important than it is when working with
stationary grinders.
11
E & C Division
SHE Manual
12
E & C Division
SHE Manual
Annexure 4
Hand Tools Safety
13
E & C Division
17.
SHE Manual
Use the right personal protective equipment (PPE) for the job.
Follow L & Ts safety manual for selecting and using safety
eyewear, steel toed shoes, gloves, hard hats, etc.
Donts
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
By following these precautions, you can help prevent injuries and provide
a better workplace for everyone.
Hand tools can cause many types of injuries:
1.
2.
14
E & C Division
3.
4.
SHE Manual
Power tools are handy helpers that people use for a variety of purposes in
all settings. They come in different styles and sizes. These tools are
useful time savers, but they're also deceptive. They can deliver a
paralyzing, or even deadly shock. They can slash, cut and mangle,
sometimes easier than larger, stationary machines.
Dos
1.
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 tool
can be turned on accidentally, penetrating a hand, arm or leg.
9.
Use proper PPE - such as safety glasses when cutting, a dust mask
when creating dust and hearing protection when noise levels are
high.
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 equipment
and plugs must be matched with outlets.
Hand Tools And Power Tools
15
E & C Division
SHE Manual
12. When working in wet areas or areas that contain flammable liquids
use only specified approved tools.
Donts
1.
2.
3.
4.
5.
6.
7.
It's easy to forget the potential dangers of power tools because they are
usually small, portable and commonly found around the shop. Many times
they're not treated with enough respect, and they are frequently left lying
around in unsafe places.
We should be as careful with power tools and portable electric tools as we
are with any other dangerous machinery. Review and remember the
following precautions:
Power tools are invaluable, timesaving devices when used properly, but
careless or improper use can cause severe injury or death. Always follow
safety instructions when operating power tools
The Power is in Your Hands - Use It Safely!
16
E & C Division
SHE Manual
Annexure 5
Pneumatic Tools Safety
Air powered tools present many of the same hazards as their electrically
powered counterparts, Electrical tools are powered from a source that
provides a well-regulated standard current. However, with air powered
tools, air may be delivered at varying pressures, flows and plus hazards
you may not have considered. Here are things to remember when using
air tools:
Dos
1. 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 muffled
loud noise of pneumatic tools can be much noisier than electric tools.
5. Frequently wipe both your hands and the tool, if oil-contaminated air
discharges near where you grip the tool.
6. Use hand gloves to avoid frostbite, stiffen your fingers, or even make
you more susceptible to certain types of cumulative trauma injuries by
cold air discharges on your hand.
7. Protect the hose from physical damage, as you may injured by
violently whipping air hose around or while scrambling to get out of its
way until the air is shut off.
8. Use goggles to protect your eyes from compressed air or particles may
fly from equipment such as chipping hammers, rock drills, rotary drills
or sanders, which cause pain or injury.
Donts
1. Avoid over oiling the tools.
2. Dont exceed the pressure/flow then the manufactures rating, the tool
itself could over-speed, delivering too much torque or other excessive
force breaking tool or work piece.
17
E & C Division
SHE Manual
18
E & C Division
16.
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
Keep containers in the store until required for use, and return
them there when you have finished with them. Store drums
upright.
Treat empty drums with as much care as full ones - they will
still Contain flammable vapour.
Hazardous substances:
Cement:
Cement mixes are a well-known cause of skin disease. Both irritant
and allergic contact dermatitis can result from proximity to wet
cement. Prolonged exposure to wet cement (for example, if you
kneel or stand in it) may cause cement burns or ulceration of the
skin.
E & C Division
SHE Manual
Protect the eyes., if any cement gets into the eyes, rinse them
immediately with plenty of warm water.
Asbestos:
Breathing in asbestos dust can kill by causing irreversible lung
damage and cancer. There is no known cure for asbestos-related
diseases. The more asbestos dust breathed in, the greater the risk
to health.
There are control limits for the various types of
asbestos. Asbestos is used in the following situations:
(a)
(b)
E & C Division
(i)
(ii)
(iii)
(iv)
(c)
SHE Manual
E & C Division
SHE Manual
Lead:
Inorganic lead is found in many construction products, e.g.
electricity cables, pipes, gutters and old lead sheet roofs. Organic
lead is added to motor fuels, and storage tanks will be heavily
contaminated.
There is a risk to health from inhaling dust or fumes created by
burning or cutting materials containing lead, including painted
surfaces, by welding, by grinding or cutting, and by spray painting
of leaded paints. Lead can be absorbed when swallowed, usually
E & C Division
SHE Manual
E & C Division
SHE Manual
10
E & C Division
17
SHE Manual
Fire Prevention
Introduction:
Fire is the most effective destroyer of plant and machinery and
crores of rupees are loss every year due to fire. Hundreds of
people lose their lives due to fire every year.
In order to prevent its occurrence, it is essential to know the
techniques of the protection, fire prevention and control measures
and fire fighting.
Fire Protection:
E & C Division
1.
2.
3.
4.
SHE Manual
The spread of the heat, smoke and toxic gases is possibly the
greatest single danger to life and takes place in much the
same manner as does the spread of fire. Smoke and toxic
gases are responsible for 66% of deaths from fire in
buildings.
E & C Division
SHE Manual
Fire Prevention
Complete steps to be taken for the prevention of fuel are
extensive. The Planning stage itself all the statutory provisions
should be in corporate.
To be effective knowledge of the chemistry of fire is essential.
Fire Prevention
E & C Division
SHE Manual
Knowing how and why a fire burns suggests ways to control and
extinguish it. The surface fire has three components that can be
controlled, while the flame fire has four components. Fires can be
controlled in the following ways:
Fire Prevention
E & C Division
SHE Manual
Cooling a Fire
To extinguish a fire by cooling, remove heat at a greater rate than
the total heat that is being evolved by the fire. To do this, the
cooling agent must reach the burning fuel directly. The cooling
action may also stop the release of combustible vapors and gases.
The most common and practical extinguishing agent is water
applied in a solid stream or spray, or incorporated in foam. In
practice, 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 but
dangerous. Fortunately, there are exception (1) Storage tanks for
flammable liquids may be arranged so their contents can be
pumped to an isolated, empty tank in case of fire. (2) When
flammable gases catch fire as they are flowing from a pipe, the fire
will go out if the fuel supply can be shut off. (3) In any mixture of
fuel gases or vapors in air, adding an excess of air has the effect of
diluting the fuels concentration below the minimum combustible
concentration point.
Limited Oxygen in a Fire
Limit air, or oxygen, from a fire by smothering the burning area
with a noncombustible material, such as covering it with a wet
blanket (make sure he blanket is not made of highly combustible
fibers), throwing dirt or sand on the fire, smothering it with inert
gas, or covering it with a chemical or mechanical foam.
To be effective, hold the blanket in place long enough for all
smoldering ignition to be extinguished. Further, smothering is
ineffective on substances containing their own oxygen supply, such
Fire Prevention
E & C Division
SHE Manual
molecules
successive
Then the
stages are
E & C Division
SHE Manual
Fire Prevention
E & C Division
SHE Manual
Classification of Fires
Four general classifications of fires have been adopted by the
NFPA. These classifications are based on the types of combustibles
and 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 of
water, or first importance in extinguishing these fires. Drychemicals agents (multipurpose dry chemicals) provide both rapid
knockdown of the flames and the formation of a coating that tends
to retard furthers combustion. Where total extinguishment is
mandatory, follow up with water.
Class B Fires
Class B fires occur in the vapor-air mixture over the surface of
flammable liquids, such as gasoline, oil grease, paints, and
thinners. The limiting of air (oxygen) or the combustion-inhibiting
effect is of primary importance to stop fires of this class before
they start. Solid streams of water are likely to spread the fire.
However, under certain circumstances, water-fog nozzles may
prove effective in the control, but not the extinguishment, of these
fires.
Generally, use regular dry chemicals, multipurpose dry
chemicals, CO2, foam or halogenated agents for such fires.
Class C Fires
Class C fires occur in or near energized electrical equipment where
non-conducting extinguishing agents must be used.
Use dry
chemicals, CO2, or halogenated extinguishing agents for such fires.
Do not use foam or a stream of water because both are good
conductors of electricity and can expose the operators to a severe
shock hazard.
Fire Prevention
E & C Division
SHE Manual
Class D fires
Class D fires occur in combustible metals such as magnesium,
titanium, zirconium, lithum, potassium, and sodium. Specialized
techniques, extinguishing agents, and extinguishing equipment
have 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 the
fire because of a chemical reaction between some extinguishing
agents and the burning metal.
Other Fires
Fire that involve certain combustible metal or reactive chemicals
require, in some cases, special extinguishing agents techniques.
Base upon these classifications various
extinguishers are manufactured and used.
types
of
portable
Fire Fighting
When all the above measures fail and a file occurs, to minimise its
effect there should be an efficient the fighting system consisting of
fixed system like the hydrants portable extinguishers and trained
personnel to man these facilities
Since all the sites do not have fixed the fighting system, portable
extinguishers 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, such
as automatic sprinklers, hydrants and standpipe hoses, and special
pipe systems for dry chemicals, CO2 Halon, and foam. Special pipe
systems for are used in areas of high fire potential where tanks for
storage of flammable liquids and electrical equipment are located.
Fire Prevention
E & C Division
SHE Manual
Fire Prevention
10
E & C Division
SHE Manual
Fire Prevention
11
E & C Division
2
SHE Manual
12
E & C Division
SHE Manual
13
E & C Division
SHE Manual
Fire Prevention
14
E & C Division
SHE Manual
Annexure 1
Remove safety catch strike the plunger against hard surface which
process either the glass bulb in case of soda acid extinguisher or
carbon dioxide cartridge.
Type B
Type C
Type D
Foam Extinguishers:
Fire Prevention
15
E & C Division
SHE Manual
Annexure 2
Type of Extinguishers
Class of Fire
Water
Foam
Water Jet
from Hose
Vaporizing
Liquid
CO2
Dry
Powder
Ordinary fire
(Wood, Rag
etc.)
Yes
Yes
Yes
No
No
No
Flammable
Liquid
No
Yes
No
Yes
Yes
Yes
Electrical
Equipment
No
No
No
Yes
Yes
Yes
Fire Prevention
16
E & C Division
18.
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
d)
(e)
(f)
(g)
The plan should set out the way in which designated people at the
site of the incident can initiate supplementary action both inside
and outside the works at an appropriate time. An essential element
On Site Emergency Plan
E & C Division
SHE Manual
of the plan must be the provision for attempting to make safe the
affected unit for example by shutting it down. On a complex site,
the plan should contain the full sequence of key personnel to be
called in from other sections or from off site.
2. Alarm and communication mechanism:
Communication is a crucial factor in handling an emergency. It is
the practice at many works that any employee can raise an
emergency alarm, so allowing the earliest possible action to be
taken to control the situation.
Alarm systems vary and will depend on the size of the works. These
should be an adequate number of points form which the alarm can
be raised either directly, by activating an audible warning, or
indirectly, via a signal or message to a permanently manned
location. The alarm should alert the incident controller (subsection
18.2.3.), who should possess the situation and implement
appropriate emergency procedures. In area where there is a high
level of noise, it may be necessary to install more than one audible
alarm transmitter or flashing lights. Automatic alarms may be
appropriate on some sites.
There should be a reliable system for informing the emergency
services as soon as the alarm is raised on site. The details of the
communication arrangements should be agreed locally; in some
cases it may be advisable to have a direct line to the fire brigade.
Predetermined code words to indicate the scale and type of the
emergency 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, often
separate from their day to day activities. The following are the key
personnel and their duties.
E & C Division
SHE Manual
E & C Division
f)
g)
h)
i)
SHE Manual
c)
d)
e)
f)
g)
h)
Apart from these personnel other works personnel will have key
roles to play in the implementation of the emergency plan. These
On Site Emergency Plan
E & C Division
SHE Manual
E & C Division
6.
7.
SHE Manual
E & C Division
SHE Manual
E & C Division
SHE Manual
10
E & C Division
SHE Manual
Annexure-1
Donts
1.
2.
3.
4.
5.
6.
Do not panic.
Do not communicate with any external unless instructed by the
Site Controller.
Do not spread unauthorized or exaggerated information to others.
Do not approach the emergency site as a spectator.
Do not engage unnecessary the communications aids like
telephone / Public Address Systems (PAS) and other means to
make the same available for handling emergency.
Do not disturb the leader assigned with specific work for handling
emergency.
11
E & C Division
SHE Manual
Annexure-2
12
E & C Division
SHE Manual
Environment Protection
In the construction site adequate measures are taken not only to fulfill all
the statutory requirements but also to conform to the norms laid down in
ISO 14001 for certification.
It is necessary to incorporate an environmental management system at
the planning stage itself so that along with the progress of site
development the attendant environmental problems are also attended to.
The environmental management system provides a structured process for
the achievement of continual development/improvement at the site; the
size and other parameters of the site will decide the rate and extent of
which.
The system consists of:
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 resources
and local and community issues will have to be dealt by the client and
Environmental Protection
E & C Division
SHE Manual
the local authorities. The E & C s role in these to identify areas and
suggest remedial measures to the client for consideration and
implementation. The action to be taken at the site on the other 4 issues
is briefly described in the following paras.
The three remaining aspects namely air, water and soil pollution are to
be considered and incorporated in the system so that, at any given time,
the pollutants under the above 3 categories do not exceed the statutory
limits.
AIR POLLUTION:
At the site, blasting, excavation, piling and concreting operations are the
essential activities undertaken and these provide air pollutant in the form
of dust.
Adequate precautions are taken to control the concentration of the
pollutants within the prescribed limits.
During blasting the explosives are placed in such a manner that the
debris fall within the site limits. In the site itself, the blasting area is
cordoned of so that the falling debris does not harm the workers.
Piling, excavation and concreting are done in wet conditions thereby
minimizing the emanation of the dust.
As regards using the Diesel Generator sets, it is ensured for the proper
performance of the set so as to keep the pollutants, Sulfur di oxide and
Carbon 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.
Environmental Protection
E & C Division
SHE Manual
Since all these work are done through contractors, the solid waste
from the canteen is collected and disposed off.
A major hazardous pollutant at the site is the wastewater collected
from the acid and alkali washing of vessels and nuetralised. The
wastewater after removal of the sediments is let out to the common
drain/soak pit.
SOIL POLLUTION:
From the above measures most of the pollutants are prevented from
getting absorbed by the soil. However the earth removed due to
activities like excavation etc; are used for levelling the ground for
making garden / planting of trees.
The organisation thus makes a conscientious effort to ensure fulfilling
all the statutory requirements to maintain a proper environment at the
work site handling, storage and transportation of hazardous materials
are dealt at the appropriate chapters.
Environmental Protection