HIRA

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES
HAZARD IDENTIFICATION AND RISK ANALYSIS (RISK)

RISK CONTENTS LIST
SL. NO. ACITIVITY PAGE NO.
CIVIL WORKS
ACTIVITY – 1 BLOCK WORKS 24
ACTIVITY – 2 CONCRETE CHIPPING 25
ACTIVITY – 3 CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER 25
ACTIVITY – 4 CONCRETING 25
ACTIVITY – 5 CONCRETE MIXTURE OPERATION 26
ACTIVITY – 6 MANUAL EXCAVATION 27
ACTIVITY – 7 MECHANICAL EXCAVATION 29
ACTIVITY – 8 ROCK BREAKING 32
ACTIVITY – 9 PLASTERING 33
ACTIVITY – 10 SHUTTERING AND SHORING 33
ACTIVITY – 11 WORK ON REBAR 34
MECHANICAL WORKS
ACTIVITY – 12 REINFORCEMENT 36
ACTIVITY – 13 SCAFFOLDING , FORMWORK AND LADDERS 36
ACTIVITY – 14 GRINDING 37
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ACTIVITY – 15 USING ENGINE GENERATOR SET 37

ACTIVITY – 16 HANDLING OF PORTABLE ELECTRICAL TOOLS 37
ACTIVITY – 17 HANDLING PORTABLE HAND TOOLS 38
ACTIVITY – 18 GAS WELDING 38
ACTIVITY – 19 ARC WELDING 39
ACTIVITY – 20 WORKING IN CONFINED SPACE 39
ACTIVITY – 21 MATERIAL HANDLING (MANUAL) 40
ACTIVITY – 22 MATERIAL HANDLING (MECHANICAL) 41
ACTIVITY – 23 WORK AT HEIGHTS 41
ACTIVITY – 24 WORKING UNDER CRANE / LIFTING EQUIPMENT. 42
ACTIVITY – 25 LOADING / UNLOADING ON TRUCK / TRAILER. 42
ACTIVITY – 26 MATERIAL HANDLING WITH CRANE 43
ACTIVITY – 27 HYDROTESTING 44
ACTIVITY – 28 HANDLING OF GAS CYLINDERS 45
ACTIVITY – 29 RADIOGRAPHY 46
GENERAL
ACTIVITY – 30 TANK ISOLATION AND CLEANING 47
ACTIVITY – 31 ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING 47
ACTIVITY – 32 STRUCTURAL WORKS 48
ACTIVITY – 33 PIPELINE WORKS 49
ACTIVITY – 34 WORKING IN HOT ENVIRONMENT 49
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ELECTRICAL
ACTIVITY – 35 WORKING IN DUSTY ENVIRONMENT 49
ACTIVITY – 36 WORKING DURING NATURAL CALAMITIES 50
ACTIVITY – 37 STAY IN CAMPS 50
ACTIVITY – 38 SLIPS, TRIPS AND FALLS AT WORK PLACE. 51
PLANT AND MACHINERY
ACTIVITY – 39 FIRE PREVENTION AND PROTECTION 51
ACTIVITY – 40 LAYING ELECTRICAL CABLES 52
ACTIVITY – 41 POLE ERECTION 52
ACTIVITY – 42 PASSAGE UNDERNEATH OVERHEAD LINES. 53
ACTIVITY – 43 WORKING NEAR OVERHEAD LINES 53
ACTIVITY – 44 ELECTRICAL INSTALLATION AND USAGE 53
ACTIVITY – 45 DENTING WORK 54
ACTIVITY – 46 DRIVING / OPERATING VEHICLES & EQUIPMENTS 55
ACTIVITY – 47 PARKING OF VEHICLES IN PARKING AREA 56
ACTIVITY – 48 EMERGENCY STARTING / JUMP STARTING 56
ACTIVITY – 49 HANDLING BATTERY 57
ACTIVITY – 50 OPERATION OF COMPACTOR 59
ACTIVITY – 51 OPERATION OF CRANE 59
ACTIVITY – 52 OPERATION OF FORKLIFT 60
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ACTIVITY – 53 OPERATION OF VIBRATOR 61

ACTIVITY – 54 REMOVAL AND REFITTING OF GEAR BOX 62
ACTIVITY – 55 CHANGING OF ALTERNATOR 63
ACTIVITY – 56 CHANGING OF HEAVY VEHICLE WHEEL 64
ACTIVITY – 57 TOWING OF DEFECTIVE VEHICLE 64
ACTIVITY – 58 SPRAY PAINTING. 65
ACTIVITY – 59 WIRE ROPE REPLACEMENT (CRANE) 66
ACTIVITY – 60 HANDLING AND LIFTING EUIPMENTS (GENERAL) 68
ACTIVITY – 61 BATCHING PLANT OPERATION 68
ACTIVITY – 62 CHIMNEY CONSTRUCTION 69
ACTIVITY – 63 GRIT BLASTING 71
ACTIVITY – 64 PRECAST YARD OPERATIONS 71
ACTIVITY – 65 FABRICATION YARD OPERATIONS 74
H.O. ACTIVITIES
ACTIVITY – 66 LIFT OPERATION AT H.O. 76
ACTIVITY – 67 MENTAL WORKLOAD AT H.O. 77
ACTIVITY – 68 USE OF VDU’s 77
ACTIVITY – 69 ILLUMINATION IN H.O. 77
ACTIVITY – 70 VENTILATION IN H.O. 77
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S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

No. FACTOR FACTOR RATING
ACTIVITY - 1: BLOCK WORKS
1 Storage of blocks 1. Height above 1.5 M 1. Fall of blocks 4 3 MODERATE 3 1. Restrict height of storage to 1.5M
2. Improper Storage 2. Personal Injury 2. Adopt cross tier system of storage.
2 Transportation of 1. Unsecured blocks 1. Breakage of blocks 3 2 LOW 2 1. Ensure blocks carried are properly secured
blocks to the site 2. Rough and uneven Road. 2. Personnel injury. 2. Defensive driving.
3 Unloading blocks 1. Fall of blocks 1. Personnel injury 4 3 MODERATE 3 1. Safe handling

2. Wrong lifting method. 2. Back pain. 2. Education of correct posture.
4 Shifting blocks to 1. Use of defective dumper 1. Damage to dumper 3 4 MODERATE 3 1. Use serviced dumper
the building site by 2. Mis-operation. 2. Tilting of dumper. 2. Deploy trained operator
dumper 3. Operate slowly and carefully on rough road
4. Provide trained banks men.
5 Shifting blocks, 1. Defective wheelbarrow 1. Overturning of wheelbarrow 3 2 LOW 2 1. Use good serviceable wheel barrow
cement mortar, 2. Loosing balance due to 2. Personnel injury. 2. Use planks wherever necessary
concrete etc., uneven / loose surface 3. Be cautious.
manually, (wheel 3. Absent mindedness 4. Concentrate on Job
borrow) 4. Hurry. 5. Know your surroundings
6 Preparation of 1. Improper handling of cement 1. Back pain 4 3 MODERATE 3 1. Follow ergonomics
cement mortar and bags. 2. Skin allergy 2. Use of adequate PPE
placing of blocks
with cement.
1.Evolution of cement dust at 1. Dust allergy to the workmen 3 3 LOW 2 1. Use of adequate PPE
work place 2. Eye/Skin injury.
2.Splashing of cement mixture.
7 Shifting of cement 1. Defective dumper 1. Damage to dumper 4 3 MODERATE 3 1. Use serviced dumper
mortar by dumper 2. Mis-operation. 2. Tilting of dumper 2. Deploy experienced operator.
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ACTIVITY - 2: CONCRETE CHIPPING
1 Chipping 1. Bad condition of tools 1. Personnel injury 2 3 LOW 2 1. Do not use defective tools. Select the right tool for
2. Foreign particles 2. Eye injury the job.
3. Tripping hazard 2. Use adequate PPE.
3. Maintain good house keeping.
4. Remove debris immediately.
ACTIVITY - 3: CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER.

1 Dismantling 1. Fall of Jack hammer. 1. Injury. 4 3 MODERATE 3 1. Hold firm.
concrete 2. Vibration. 2. Prolonged exposure causes 2. Secure chisel firm to jack.
(foundation) occupational disease called white 3. Rotation of work force to avoid prolonged
finger exposure.
ACTIVITY - 4: CONCRETING.
1 Concreting 1. Air pollution by cement. 1. May affect Respiratory System. 3 3 MODERATE 3 1. Wear respirators or cover mouth and nose with wet
2. Handling of ingredients. 2. Hands may get injured. cloth.
3. Protruding reinforced rods. 3. Feet may get injured. 2. Use gloves and other PPE.
4. Earthing of electrical mixers, 4. Can cause electrocution/ 3. Use Safety shoes.
vibrators etc. not done. asphyxiation. 4. Provide platform with wooden planking above
5. Falling of materials from 5. Persons may get injured. reinforcement for movement of workers.
height. 6. Causes tiredness of workers and 5. Ensure earthing of equipments and proper
6. Continuous pouring of by may lead to accident. functioning of electrical circuit before commencement
same gang. 7. Parts of body or clothes may get of work .
7. Revolving of concrete mixer/ entrapped. 6. Use hard hats.
vibrators 7. Remove surplus material immediately from work
place.
8. Ensure lighting arrangement during night hours.
9. Insist on shift pattern .
10. Provide adequate rest to workers between
subsequent pours.
11 .Allow only mixer with hooper.
12. Provide safety cages around moving motors .
13. Ensure proper mechanical locking of vibrator.
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S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISK LEVEL RISK CONTROL MEASURES
2 Super- structure 1. Air pollution by cement. 1. Shuttering /props may collapse and 4 3 MODERATE 3 1. Use PPE like gloves, shoes, helmets,etc.
2. Handling of ingredients. prove fatal. 2. Avoid usage of make-shift tools.
3. Protruding reinforced rods.
4. Earthing of electrical mixers,
vibrators etc. not done.
5. Falling of materials from
height.
6. Continuous pouring of by
same gang.
7. Revolving of concrete mixer/
vibrators
8. Deflection in props or
shuttering material
3 Access to 1. Passage to work place 1. Improperly tied and designed 3 3 MODERATE 3 1. Ensure the stability and strength of passage before
workplace props/planks may collapse. commencement of the work.
2. Do not overload or stand under the passage.
ACTIVITY - 5: CONCRETE MIXTURE OPERATION

1 Deployment of 1. Poor mechanical condition of 1. Failure of equipment. 3 4 MODERATE 3 1. Use good serviced equipment .
concrete pump the equation. 2. Accident /personal injury 2. Deploy only licensed operators.
2. Unauthorized operation 3. Engage banks man.
2 Batching plant. 1.Poor mechanical condition of 1. Failure of equipment. 4 3 MODERATE 3 1. Use good serviceable equipment.
Truck Mixer. the equipment. 2. Accident /personal injury 2. Deploy only licensed operators.
Cement bulk 2. Unauthorized Operation 3. Engage Banks man.
carrier.
3 Deployment of 1. Improper placement of mixer 1. Tilting of mixure. 4 3 MODERATE 3 1. Ensure concrete mixer is placed on even surface
concrete mixture. machine on uneven surface . 2. Damage to concrete mixer. with proper pegs.
2. Mis-operation. 3. Electrical shock. 2. Check for proper electrical connections and
3. Loose contact with electric 4.Fire hazard . insulation.
connections. 5. Personnel injury. 3. Keep adequate fire extinguishers.
4. Rotating parts of machine. 6. Unwanted movement of concrete 4. Proper guards at all rotating parts of machinery.
5. Unblocked wheels of truck. 5. Position the mixer machine to disperse smoke
concrete mixer. 7. Mis- operation and injury to crew. easily into atmosphere.
6. Improper coordination among 8. Breathing problems. 6. Clean the mixer machine after the concreting is
crew members. over.
7. Smoke from the exhaust.
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ACTIVITY - 6: MANUAL EXCAVATION
1 Piling Work 1. Failure of pile- driving 1. Can hurt people . 2 3 LOW 2 1. Inspect Piling rigs and pulley blocks before the
equipment . 2. Can cause deafness and beginning of each shift.
2. Noise pollution. psychological imbalance. 2. Use personal protective equipment like ear plugs,
3. Extruding rods/ casing . 3. Can hurt people. muffs, etc.
4. Working in the vicinity of 4. Can cause electrocution 3. Barricade the area and install sign boards.
'Live- Electricity ' /Asphyxiation 4. Keep sufficient distance from Live Electricity as per
IS code.
5. Shut off the supply, if possible.
2 Pit Excavation up 1. Falling into pit. 1. Personal injury. 3 4 MODERATE 3 1. Provide guide rails/ barricade with warning signal.
to 3m 2. Earth collapse. 2. Suffocation / Breathlessness. 2. Provide at least two entries/ exits.
3. Contact with buried electric 3. Buried. 3. Provide escape ladder.
cables. 4. Electrocution. 4. Provide suitable size of shoring and strutting if
4. Gas / Oil Pipelines 5. Explosion required .
5. Keep soil heaps away from edge equivalent to 1.5m
or depth of pit whichever is more.
6. Don't allow vehicles to operate too close to
excavated areas . Maintain atleast 2m distance from
edge of cut..
7. Maintain sufficient angle of repose. Provide slope
not less than 1:1 and suitable bench of 0.5m width at
every 1.5m depth of excavation in all soils except
hard rock.
8. Battering/Benching the sides.
9. Obtain permission from competent authorities , prior
to excavation , if required.
10. Locate the position of buried utililty by referring to
plant drawings.
11. Start digging manually to locate the exact position
of buried utility and thereafter use mechanical means.
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3 Pit excavation 1. Falling into pit. 1. Personal injury. 3 4 HIGH 4 1. Prevent ingress of water
beyond 3m. 2. Earth collapse. 2. Suffocation / Breathlessness. 2. Provide ring buoys.
3. Contact with buried electric 3. Buried. 3. Identify and provide suitable dewatering pump or
cables. 4. Electrocution. well point system.
4. Gas / Oil Pipelines 5. Explosion 4. Obtain prior approval of excavation method from
3. Flooding due to excessive 6. Can cause drowning situation . local authorities, if required.
rain/ underground water. 7. Building / structure may collapse . 5. Use under-pining method .
4. Digging in the vicinity of the 8. Loss of health and wealth. 6. Barricade the excavated area with proper lighting
existing building / structure . 9. May cause cave-in or slides. arrangements..
5. Movement of vehicles / 10. Persons may get buried. 7. Maintain at least 2m distance from edge of cut and
equipments close to the edge of use stop blocks to prevent over-run .
cut. 8. Strengthen shoring and strutting.
4 Rock excavation 1. Improper handling of 1. May prove fatal. 4 4 HIGH 4 1. Ensure proper storage, handling and carrying of
by blasting explosives. 2.. May cause severe injuries or explosives by trained personnel.
2. Uncontrolled explosion. prove fatal. 2. Comply with the applicable explosive acts and
3. Scattering of stone pieces in 3. Can hurt people . rules.
atmosphere. 4. May cause severe injuries 3. Allow only authorized persons to perform blasting
4. Entrapping of animals / 5. May explode suddenly. operations.
persons . 4. Smoking and open flame are to be strictly
5. Misfire prohibited.
5. Use PPEs like gloves, goggles, face mask, etc.
5. Barricade the area with red flags and blow siren
before blasting .
6. Do not return to site for atleast 20min. or unless
announced safe by designated person.
5 Narrow deep 1. Frequent cave-in or slides. 1. May cause cave-in or slides.. 4 3 MODRATE 3 1. Battering / benching of sides .
excavations for 2. Flooding due to Hydrostatic 2. Persons may get buried. 2. Provide escape ladders.
pipelines, etc. testing 3. May cause severe injuries or prove 3. Bail out accumulated water.
fatal. 4. Maintain adequate ventilation .
4. May arise drowning situation
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No. ACTIVITY HAZARD CONSEQUENCE FACTOR FACTOR RISKLEVEL RATING CONTROL MEASURES
ACTIVITY - 7: MECHANICAL EXCAVATION
1 Excavation using 1. Defective machinery 1. Damage to the machinery 3 5 HIGH 4 1. Adhere to Permit to Work System if applicable.
machinery 2. Miss-operation 2. Damage to underground electrical, 2. Check machine thoroughly before starting the job.
3. Inadvertent operation telecom cables and water services. 3. Use good and serviced machines.
4. Working near the edge of 3. Fall of machinery into the pit. 4. Look for route markers.
excavation 4. Pipe lines rupture/explosion injury. 5. Make trial pits and expose underground cables, if
5. Working near utilities. 5. Shock/Fatality any.
6. Working near overhead lines. 6. Fatal injury 6. Look for warning tapes, cable covering mats
7. Fall of heavy objects Stone, 7. Lung complaints concrete saddles and padding.
boulder, soil etc. into excavated 8. Eye injuries. 7. Use cable detectors.
pit. 9. Hit injuries. 8. Adhere strictly to manual excavation in case
8. Fall of persons into the pits. 10. Hearing impairment. underground cables are present.
9. Dust. 11. Injury due to hit or collision. 9. Follow safety procedure.
10. Congested work site, too 12. Hit and damage to overhead 10. Operate machinery, keeping safe distance to
many persons working in the structure. avoid excavation area landside.
pits or trenches. 11. Deploy trained banks man.
11.Noise during rock breaking, 12. Keep away from the edge of the excavation.
heavy equipment operation. 13. Provide barrier away from the edge of excavation.
14. Provide sign boards and blinking lights.
15. Edge of excavation shall be 0.5 m away from
high-pressure lines.
16. Keep 1.5 m away from overhead LT lines.
17. Use only approved equipment and competent
operators.
18. No entry into the pit during excavation.
19. Keep removed earth at least 1m away from the pit.
20. Provide shuttering/shoring.
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21. Remove the excavated earth immediately.
22. Do not keep heavy objects on the edge of the pit.
23. Provide barricading with warning signals ( warning
light at night)
24. Provide proper ladder to get into the pits.
25. Provide walkway for lengthy trenches.
26. Use dust mask and goggles.
27. Allow only minimum number of persons to work at
the same time.
28. Train for safe manual working procedures.
29. Provide adequate emergency access always.
30. Use earplugs or earmuffs.
31. Provide trained banks man.
32. Keep distance of minimum 5m between two
equipment while in use.
33. Use only approved equipment and employ
competent operators.
34.Keep safe overhead distance.
35. Observe special permits wherever required.
36. Strictly adhere to banks men signals and
directions.
2 Incomplete 1. Un-noticed hazard area. 1. Fall of persons/animals into the pit. 3 4 MODERATE 3 1. Impart proper instruction to all workmen.
excavation. 2. Improper barricading. 2. Fall of machinery into pit. 2. Proper demarcation around the pit.
3. Bad weather. 3. Landslide due to weather effect. 3. Keep sign board "Danger".
4. Barricade pits / trenches.
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ACTIVITY - 8: ROCK BREAKING
1 Rock excavation 1. Jolts to operator. 1. Ill health. 4 3 MODERATE 3 1. Employ trained operator with license.
using pneumatic 2. Obstruction to vision between 2. Damage, injury to facilities and 2. Avoid applying excessive force to hammer to avert
equipment, rock operator and banks man. people jolting.
breaker, 3. Flying Projectiles. 3. Injury/Damage to asset. 3. Banks man to stand in direct view with operator.
excavators. 4. Noise. 4. Hearing impairment. 4. Extreme care to prevent projectiles flying from
5. Dust. 5. Pulmonary disorders. hammer point.
6. Excavated Trench 6. Fall of material, equipment, 5. Do not operate the hammer if window cabin or
persons and animals shield is not in place.
6. Use ear muff / plug.
7. Use dust mask / Balaclava.
8. Barricade the area with warning sign.
9. Ensure overnight safety.
10. Provide ladder for deep pits.
2 Removal of 1. Hydraulic pressure jet 1. Loss of Hydraulic oil. 3 2 LOW 2 1. Disconnect Hydraulic hose only after closing
Hydraulic Hammer 2. Environmental impact pressure and return line stop valves.
3 Laying hammer 1. Fall. 1. Physical injury & back pain. 3 4 MODERATE 3 1. Position the hammer horizontal on wooden block
down and remove pins by gentle tapping.
4 Working near 1. Fall of hammer on nearby 1. Damage to Hammer chisel. 2 5 HIGH 4 1. Employ trained and licensed operator.
overhead lines and facilities. 2. Physical injury. 2. Careful operation.
pressure lines 2. Overhead lines. 3. Damage to assets. 3. Edge of excavation shall be 0.5m away from high-
3. Hitting, striking, reversing 4. Shock. pressure pipelines.
incidents. 5. Fatal injury 4. Keep 1.5 m away from overhead LT lines.
5. Strict adherence to conditions stipulated by
excavation work permit.
6. Keep adequate signboards and barricade the area.
7. Keep work force 5m away from Rock Breaker.
8. Strict adherence to Banks man's instructions.
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ACTIVITY - 9: PLASTERING
1 Plastering/ 1. Inhalation of cement dust. 1. Bronchial disease 4 3 LOW 2 1. Wear respiratory protection.
Grouting 2. Absorption of cement 2. Irritation 2. Wear safety goggles and coverall.
3. Ingestion. 3. Prolonged exposure causes 3. Wash hands before taking food
dermatitis. 4.Take shower after reaching camp.
4. Gastro-intestinal disorders.
ACTIVITY - 10: SHUTTERING AND SHORING

1 Shuttering / 1. Protruding nails. 1. Personal injury. 3 4 MODERATE 3 1. Avoid Protrusion/projection of sharp edges.
Handling of 2. Unsafe / Improper handling. 2. Tripping/Slipping hazard. 2. Secure the load properly.
wooden planks 3. Improper house keeping 3. See that there is no strain on back.
and supports.
2 Cutting wood to 1. Misuse of cutting device. 1. Hand injury . 3 3 LOW 2 1. Deploy trained carpenter.
required size. 2. Fall of tools & wood from 2. Improper cutting resulting in
height. material loss.
3. Personnel injury.
3 Preparation of 1. Flying nails while hammering. 1. Eye injury. 3 4 MODERATE 3 1. Wear safety goggles.
shuttering on 2. Use of loose hammer. 2. Flying of hammer head resulting in 2. Ensure that hammer handle is properly wedged and
ground. personnel injury hammer is in good condition.
3. Keep persons away from hammering area.
4 Erection of 1. Fall of shuttering 1. Physical injury & back pain. 2 4 MODERATE 3 1. Erection should be done standing over firm
shuttering. supports.
5 Erection of 1. Fall of person or shutter. 1. Personal injury 3 4 MODERATE 3 1. Use approved scaffolding.
shuttering on 2. Fall of loose materials. 2. Damage to the shutter. 2. Do not keep away loose material on platform.
height. 3. Loss of materials. 3. Deploy experienced workers.
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6 De-shuttering & De- 1. Fall of shuttering. 1. Injury to persons. 2 3 LOW 2 1. Deploy experience workers.
shoring 2. Protruding nails. 2. Keep and alert third party persons to be away from
3. Loose nails on floor. the de-shuttering area.
3. Remove nails and stack shuttering materials
properly.
4. Keep all removed nails in one container.
5. Maintain good housekeeping.
ACTIVITY - 11: WORK ON REBAR

1 Manual bar 1. Defective tools 1. Personnel injury. 2 3 LOW 2 1. Do not use sub-standard tools.
bending. 2. Wrong application of tools. 2. Damage to tools. 2. Ensure usage of right tools for right job.
3. Wrong posture. 3. Back pain. 3. Do not push tools while bending.
4. Hold firmly.
5. Adhere to correct and safe posture
2 Bar bending on 1. Defective machinery. 1. Personal injury 3 3 LOW 2 1. Do not use defective tools.
bending machine 2. Difference in level between 2. Damage to the machine. 2. Secure machine and table on level ground.
table and machine. 3. Damage to the table. 3. Keep area clear around machine.
3. Improper guard. 4. Misoperation. 4. Provide switch for emergency stoppage.
4. Inexperienced operator. 5. Ensure guards are provided on all rotating parts.
6. Hold the bars firmly.
7. Stack bars properly and away from machine.
3 Manual cutting 1. Toppling of chisel. 1. Personal injury. 3 4 MODERATE 3 1. Safe handling of tools.
2. Slippage of bar under 2. Flying bar. 2. Keep hand away from cutting chisel.
tension. 3. Hold bar firmly.
4. Ensure safety while operating handle.
4 Binding bar with 1. Haphazard placement of 1. Personal injury 3 3 LOW 2 1. Keep wires initially bend downward.
wire steel bar.
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5 Cutting bar by 1. Defective machine. 1. Personnel injury. 4 3 LOW 2 1. Do not use defective tools.
machine 2. Improper guard. 2. Damage to the machinery. 2. Use serviced machine.
3. Loose electrical connections. 3. Personnel injury. 3. Provide stand on both sides of the machine for
4. Defective blade. 4. Fire hazard. moving steel.
5. Personnel injury 4. Provide switch for emergency stoppage of machine.
5. Ensure proper electrical connections.
6. Do not use defective blade.
7. Keep hands away from cutting blade while in
operation.
6 Cuting wire by 1. Defective tools. 1. Personal injury. 3 3 MODERATE 3 1. Use proper binding.
tools. 2. Damage of tools. 2. Take extra care while walking around the work site
7 Manual placement 1. Loose binding of 1. Slippage of binding steel 3 3 LOW 2 1. Ensure proper binding .
of bar. reinforcement . reinforcement. 2. Give proper instructions.
2. Improper co-ordination. 2. Personal injury. 3. Deploy trained and experienced persons.
3. Inexperienced persons. 4. Ensure proper co-ordination among the crew.
5. Avoid sharp edges.
ACTIVITY - 12 REINFORCEMENT
1 Reinforcement 1. Curtailment and binding of 1. Persons may get injured . 3 3 MODERATE 3 1. Use PPE like gloves, shoes, helmets,etc.
rods. 2. Workers may get injured on their 2. Avoid usage of make-shift tools.
2. Carrying of rods for short hands and shoulders. 3. Provide suitable pads on shoulders and use safety
distances/ at height. 3. Rods may cut or injure the fingers. gloves.
3. Checking of clear distance/ 4. Persons may get injured and fall 4. Tie up rods in easily lift able bundles.
cover with hands. down . 5. Ensure proper staging.
4. Hitting projected rods and 5. May prove fatal. 6. Use measuring devices like tape ,measuring
standing on cantilever rods. 6. Protruded rods may hit the persons rods,etc.
7. Use safety shoes and avoid standing unnecessarily
on cantilever rods.
8. Avoid wearing of loose cloths.
9. Provide safety nets.
2 Transportation of 1. Fall of material from height. 1. Personal injury 4 3 MODERATE 3 1. Use red flags / lights at the end s.
Rebar 2. Hit by protruding bar 2. May prove Fatal 2. Do mot protrude the rods in front of or by the side of
3. Damage to Material/property the drivers cabin.
3. Do not extend the rods 1/3rd. of deck length or
1.5m whichever is less.
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ACTIVITY - 13 SCAFFOLDING , FORMWORK AND LADDERS
MODERATE
Scaffolding ,
formwork and
1. Person can fall down . 1. Person may sustain severe injuries
2. Failure of scaffolding material. and prove fatal.
4 3 3 1. Provide guard rails for working at height .
2. Face ladder while climbing and use both hands.
1
ladder 3. Material can fall down 2. Persons working at lower level get 3. Ladder shall extend about 1m above landing for easy
injured. access and tying up purpose.
4. Do not place the ladder against a movable objects and
maintain base at 1/4 ratio of the working length of the
ladder.
5. Suspended scaffolds shall not be less than 500mm
wide and tied securely with ropes.
6. No loose planks shall be allowed.
Use PPE, like helmets, safety shoes etc.
7.
Design scaffo
10.
Scaffolding pla
secured and m
11.
Don't overload
12.
Do not join sh
Remove excess material and scrap immediately
8.
Inspect visual
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ACTIVITY - 14: GRINDING
1 Grinding and 1. Grinding without goggle. 1. Injury to eyes by flying chips. 3 4 MODERATE 3 1. Use proper PPE.
grinding wheel 2. Absence of tool rest on 2. Accident and injury 2. Mount the tool rest on both sides.
replacing. bench grinder. 3. Replace the wheel.
3. More gap between the wheel 4. Gap more than 3mm is unsafe.
and tool rest of bench grinder. 5. Use grinding wheel of correct size.
4. Improper /wrong size grinding 6. Training & instruction.
wheel. 7. Provide fire extinguisher.
5. Excess pressure on wheel. 8. Use fire blanket to cover nearby vents, drains, open
6. Breakage of wheel. ends of pipes.
9. Application of mud plug prior to pipe after cold
cutting.
10. Proper tightening of wheel.
11. Use of correct size spacer washers.
ACTIVITY - 15: USING ENGINE GENERATOR SET

1 Use of Engine 1.Improper earthing . 1. Electrical shock/ burn injury. 2 5 HIGH 4 1. Proper earthing.
Generator Set for 2. Improper insulation. 2. Fire/Explosion. 2. Adequate insulation (check).
ARC-welding. 3. Faulty appliances/control 3. Asphyxiation 3. Proper preventive maintenance.
system. 4. Poisoning. 4. Ventilation
4. Poor exhaust. 5. Periodical gas testing and monitoring at all areas.
5. Poor ventilation. 6. Prevent leakages. Check before use.
6. Hydrocarbons.
7. Oil leakages.
8. Toxic gases.
ACTIVITY - 16: HANDLING OF PORTABLE ELECTRICAL TOOLS

1 Working with 1. Damaged cable . 1. Electric shock. 3 4 MODERATE 3 1. Daily check up before start.
portable electric 2. Defective tool. 2. Spark /shock. 2. Replace defective tools.
tools 3. Loose components (wheel, 3. Hit injury. 3. Proper maintenance.
switch) 4. Accident and injury. 4. Training on proper use & care.
4. Excess pressure on tool. 5. Bodily injury. 5. Inspection and corrective action to follow correct
5. Improper handling. 6. Shock/eye and bodily injuries. handling procedures.
6. Non use of PPE. 6. Use adequate PPE (Face shield/googles, gloves)
37

ACTIVITY - 17: HANDLING PORTABLE HAND TOOLS
1 Working with 1.Defective / damaged tools 1. Accident and bodily injuries. 4 3 MODERATE 3 1. Replacing defective / damaged tools.
portable hand and tools without protective 2. Property damages. 2. Use tools only with protective handles.
tools. handles. 3. Training & instruction to use right tool for the right
2. Improper handling. job.
3. Improper storage. 4. Keep tools only in toolboxes.
4. Misuse /abuse. 5. Training & instruction to use right tools for the right
job.
ACTIVITY - 18: GAS WELDING

1 Gas welding / 1. Welding radiates invisible 1. Radiation can damage eyes and 2 5 HIGH 4 1. Use specified shielding devices and other PPE of
cutting / heating. ultraviolet and infrared rays. skin. correct specifications.
2. Improper placement of 2. Explosion may occur. 2. Avoid throated tungsten electrodes for GTAW.
oxygen and acetylene cylinders. 3. May cause fire. 3. Move out any leaking cylinder.
3. Leakage /cuts in hoses. 4. Cylinder may burst. 4. Keep trolley for transportation of cylinders and
4. Opening - up of cylinder. chain them .
5. Welding of tanks, container 5. Use flashback arrestors.
or pipes storing flammable 6. Purge regulators immediately and then turn off.
liquids. 7. Never use grease or oil on oxygen line connections
and copper fittings on acetylene lines.
8. Inspect regularly gas carrying hoses.
9. Always use red hose for acetylene and other fuel
gases and blue for oxygen.
10. Always stand back from regulator while opening
the cylinder.
11. Turn valve slowly to avoid bursting.
12. Cover the lug terminals to prevent short circuiting .
13. Empty & purge them before welding.
14. Never attach the ground cable to tanks, container
or pipe storing flammable liquids.
15. Never use LPG for gas cutting.
38

ACTIVITY - 19: ARC WELDING
1 Arc welding 1. Radiation harmful to naked 1. Welder's cataract. 2 5 HIGH 4 1.Use welding shield / goggles.
eyes. 2. Burn injury. 2. Fireproof apron / gloves / screen.
2. Splinters / slag. 3. Lung ailments 3. Ventilation (local or exhaust if possible)
3.Toxic flames. 4. Dermatitis. 4. Full-sleeved coverall and gloves.
4. Dislocation / fall of job piece 5. Hit injury / crush injury. 5. Proper clamping system / material handling
due to faulty clamping. 6. Electric shock. techniques.
5. Loose connections / Loss of 7. Fire / explosion. 6. Use shock proof boots and hand gloves.
insulation. 8. Asphyxiation. 7. Provide earthing to the plant.
6. Flammable gases. 8. Periodical gas testing.
7. Poor ventilation 9. Keep fire extinguisher (DCP/CO2) standby.
10. Adequate ventilation.
11. Training & instructions.
ACTIVITY - 20: WORKING IN CONFINED SPACE

1 Working in confined 1. Suffocation / drowning. 1. Unconsciousness, death. 1 5 HIGH 4 1. Use respiratory devices, if required.
spaces (tank, 2. Presence of foul smell and 2. Inhalation can pose threat to life. 2. Avoid over crowding inside a confined space.
vessel, static toxic substances. 3. Person may sustain burn injuries or 3. Provide exhaust fans for ventilation.
equipment, 3. Ignition/ flame can cause fire. explosion may occur. 4. Do not wear loose clothes, neck ties, etc.
excavation beyond 5. Fulfill conditions of the permit.
3m etc) 6. Check for presence of hydrocarbons and oxygen
level.
7. Obtain work permit before entering a confined
space .
8. Ensure that the connected piping of the equipment
which is to be opened is pressure free, fluid has been
drained, vents are open and piping is positively
isolated by a blind flange.
39
9. Check for hydrocarbon and Aromatic compounds
before entering a confined space.
10. Depute one person outside the confined space for
continuous monitoring and for extending help in case
of an emergency.
11. Keep the fire extinguishers at hand distance.
12. Remove surplus material and scrap immediately .
13. Do not smoke inside a confined space.
14. Do not allow gas cylinders inside a confined
space.
15. Use low voltage (24V) for hand held lighting.
16. Use tools with air motors or electric tools with max.
voltage of 24V.
17. Remove all equipments at the end of the day.
ACTIVITY - 21: MATERIAL HANDLING (MANUAL)

1 Material handling 1. Non-use of PPE. 1. Accident/ injury. 3 4 MODERATE 3 1. Use adequate PPE.
(manual) 2. Inadequate manpower. 2. Back pain,sprain,etc. 2. provide adequate manpower for lifting of heavy
3. Lack of co-ordination in 3. Property damage. loads.
group effort. 4. Injury /property damage. 3. Training & instructions.
4. Wrong body posture. 5. Loss of property. 4. Use hand gloves/ packing materials.
5. Lifting error. 5. Remove protruding nails before handling.
6. Sharp edges / corners / 6. Use proper lifting devices for good grip.
projecting parts / protruding 7. Fasten the item properly or use suitable packing /
nails. container.
7. Slippery materials.
8. Loose materials.
40

ACTIVITY - 22: MATERIAL HANDLING (MECHANICAL)
1 Material handling 1. Lack of knowledge / skills. 1. Accident / injury. 2 4 MODERATE 3 1. Only competent and approved operator shall be
with forklift , hydra, 2. Defective equipment. 2. Material losses. deployed for equipment operations.
crane etc. 3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent
4. Overloading. 4. Injury due to accident and property person before deployment.
5. Untrained operator. damage. 3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banks men / rigger.
ACTIVITY - 23: WORK AT HEIGHTS

1 Working at 1. Person can fall down. 1. May sustain sever injuries or prove 2 5 HIGH 4 1. Provide guard rails/ barricade at the work place.
elevated places. 2. Material can fall down fatal . 2. Use PPE like full body harness, life line, helmets,
2. May hit the scrap/ material stacked safety shoes, etc.
at the ground or in between . 3. Obtain the permit before starting the work at height
3. May hit the workers working at above 3m.
lower levels and prove fatal. 4. Fall arrest and safety nets, etc, must be installed.
5. Provide adequate working space (min.0.6m).
6. Tie / weld working platform with fixed support .
7. Use roof top walk ladder while working on a
slopping roofs.
8. Avoid movement on beams.
9. Keep the work place neat and clean.
10. Remove the scrap immediately.
11. Do not throw or drop materials or equipment from
height. i.e. do not bomb materials.
12. All tools to be carried in a tool- kit Bag or on
working uniform.
13. Remove scrap from the planks.
14. Ensure wearing of helmet by the workers working
at lower levels.
41

ACTIVITY - 24: WORKING UNDER CRANE / LIFTING EQUIPMENT.
1 Working under 1. Working without PPE. 1. Fatality / injury due to fall of loads. 2 5 HIGH 4 1. Use required PPE.
crane / lifting 2. Failure of slings. 2. Material damage. 2. Use only certified slings as per color coding.
equipment 3. Improper handling. 3. No person to stand under lifted load.
4. Overloading. 4. Follow safe lifting procedures.
5. Defective equipment. 5. Only approved equipment to be used.
6. Lack of awareness. 6. Ensure proper servicing.
7. Training to operator and providing banks man /
rigger for assistance.
ACTIVITY - 25 LOADING / UNLOADING ON TRUCK / TRAILER.

1 Loading and 1. Loaded material due to fall. 1. Accident / injury 1 5 HIGH 4 1. Follow lifting procedure.
unloading of 2. Defective equipment. 2. Damage of materials. 2. Use correct equipment & lifting tackles.
materials on 3. Overloading 3.Damage to equipment. 3. Supervision by competent persons.
trucks / trailers. 4. Provide trained banks men/rigger.
5. Do not jump out from vehicle till clearance is
obtained.
6. Proper supervision.
7. Refer to load chart.
8. Use platform ladder for safe access.
9. Never deactivate over riding devices
on lifting equipment.
2 Loading near live 1. Live facilities / OH lines etc. 1. Fire 2 5 HIGH 4 1. Keep Safe distance from Live facilities.
facilities 2. Electric shock.
3. Injury.
4. Property Damage
42

ACTIVITY - 26: MATERIAL HANDLING WITH CRANE
1 Crane positioning 1. Outriggers on soft 1. Tilting of crane & consequent 3 4 MODERA 3 1. Outrigger base plates to rest on firm ground or on
ground/loose soil damage & loss. TE timber blocks/ steel plates
2 Operating of PTO 4 MODERATE 3 1. Make sure control levers are all in neutral position
1. Operating levers not in
neutral position.
1. Inadvertent operation of crane on
engagement of PTO
2
3 Extending 1. Outriggers not extended fully 1. Tilting of the crane. 2 4 MODERATE 3 1. Extend outrigger fully.
outriggers 2. Outrigger not locked. 2. Retracting of outriggers & tilting of 2. Lock the outrigger beam.
the crane
5 Passage under OH 1. High tension electric current . 1. Electric shock. 1 5 HIGH 4 1. No movement with raised boom
lines with raised 2. Traveling with load. 2. Fall of load & tilting of crane. 2. Provide Banks man
boom 3. Do not travel with lifted load.
4 Loading operation 1. Side loading / dragging of 1. Tilting of the crane due to uneven 2 5 HIGH 4 1. Lifting only vertically.
load. load. 2. No dragging of load.
2. Overload. 2. Damage to crane and loss of 3. No overload.
3. Swinging the load. materials. 4. No swinging of load.
4. Abrupt operation of control 3. Instability & tilting of crane. 5. Operate the levers slowly and smoothly.
levers. 4. Jerking, fall of load, hitting person. 6. Do not keep the load in the elevated position.
5. Keeping the load in the 5. Fall of load due to mechanical 7. Do not allow any person to be under the load.
elevated position. failures. 8. No movement with raised boom.
6. Persons standing below the 6. Fall of load causing human injuries. 9. Provide Banks man.
lifted load. 7. Electric shock. 10. Do not travel with lifted load.
8. Fall of load & tilting of crane.
43

ACTIVITY - 27: HYDROTESTING
1 Testing 1. Bursting of piping. 1. May cause injury and prove fatal. 4 4 HIGH 4 1. Prepare test procedure and obtain EIL/owner's
2. Collapse of tanks. approval.
3. Tanks flying off. 2. Provide separate gauge for pressurizing pump and
piping / equipment .
3. Check the calibration status of all pressure gauge,
dead weight testers and temperature recorders.
4. Take dial reading at suitable defined intervals and
ensure most of them fall below 40-60% of the gauge
scale range.
5. Provide safety relief valve.( set at pressure slightly
higher than test pressure ) while testing with air/
nitrogen.
6. Ensure necessary precautions, stepwise increase in
pressure , tightening of bolts/nuts, grouting, etc
before and during testing.
7. Keep the vents open before opening any valve
while draining out of water used for hydro testing of
tanks.
8. Pneumatic testing involves the hazards of released
energy stored in compressed gas. Specific care must
therefore be taken to minimize the chance of brittle
failure during a pneumatic leak test. Test temperature
is important in this regard and must be considered
when the designer chooses the materials of
construction.
2 Pumping 1. High pressure water. 1. Injury / fatality due to failure of 2 5 HIGH 4 1. Check pressure relief valve.
operation . pressurized system. 2. Calibrated pressure gauge.
3. Monitor pressure rise.
4. Do not stand in line with the flange.
3 Pressurizing the 1. Hydrocarbons. 1. Fire & explosion. 2 5 HIGH 4 1. Gas testing before pumping.
system 2. High pressure water in the 2. Injury due to bursting of the flange 2. Tightening / loosening only after depressurizing the
pressure lines, hose etc. coupling. pressure line.
leaking due to rupture of hose 3. Barricading the pressurized system to prevent entry
or couplings. to other workers.
4. Permit to work & hot work permits.
44
4 Tightening flange 1. Flanges & bolts under 1. Hitting of thrown out flange & injury. 2 5 HIGH 4 1. Tighten / Loosen the bolts only web no pressure in
bolts under high pressure. the system.
pressure. 2. Check flange bolts for adequate strength & size.
5 Release of 1. Bursting of flange joint 1. Physical Injury Environment 4 3 LOW 2 1. Drain the water by standing away from the line of
pressure and 2. Flying flanges hitting persons pollution released water jet.
Disposal of hydro- 3. Hit by Water jet from the 2. Eye Injury 2. Draining & conveying of water through flexible hose
tested water nozzles in the eyes 3. Environmental pollution up to the disposal well.
4.Chemicals / pollutants in
water due to adding of
chemicals in plant water.
ACTIVITY - 28: HANDLING OF GAS CYLINDERS

1 Transporting gas 1. Cylinders kept horizontal. 1. Fire and explosion by leakage and 2 5 HIGH 4 1. Keep charged cylinder only.
cylinders: 2. Cylinder kept untied property damage. 2. Keep vertically and tie with chain to a fixed
* Oxygen /unlocked in welding truck 2. Gas leakage due to valve damage. structure.
* Acetylene. /mobile welding unit. 3. Human injury by fall of cylinder. 3. Keep in specially fabricated cage to prevent fall.
* Argon. 3. Valve leakage. 4. Damage to cylinder/valve. 4. Keep valve cap in position during transportation.
* Nitrogen. 5. Leakage of gas. 5. Different types of gas cylinders not to be loaded in
* LPG. the same vehicle at a time.
6. Only authorized vehicle and specially trained driver
shall be engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked
independently on truck to prevent falling of one
cylinder while loading/unloading the other.
45

ACTIVITY - 29: RADIOGRAPHY
1 Radiography on 1. Ionizing radiation. Radiations may react with the skin and 2 5 HIGH 4 1. Employ only approved agency to carry out the work.
welded joints. 2. Transportation and storage of can cause cancer, skin irritation, 2. Ensure Safety related regulation as per
Radiography source. dermatitis etc. BARC/AERB before commencement of job.
Loss of Radio isotope 3. Cordon off the area and install Radiation warning
symbols.
4. Restrict the entry of unauthorized persons.
5. Wear appropriate PPE and film badges issued by
BARC/AERB.
6. Never touch or handle radiography source with hands.
7.
Store radiogra
pit should be a
Radiography source should never be carried in
46
General Activities
No. ACTIVITY HAZARD CONSEQUENCE FACTOR FACTOR RISKLEVEL RATING CONTROL MEASURES
ACTIVITY - 30: TANK ISOLATION AND CLEANING
1 Working in 1. Inadequate access to 1.Inability to escape. 2 5 HIGH 4 1. Ensure emergency access and rescue plants
confined space outside. 2. Inability to contact the standby before entry.
(tanks/vessels) 2. Lack of communication. man. 2. Maintain uninterrupted contact with the workers by
3. Tools sticking due to 3. Injury/fatality the standby person.
congested work place. 4. Exhaustion or other heat ailments. 3. Ensure buddy system.
4. Heat stress. 5. Asphyxiation. 4. Keep only minimum number of persons for work.
5. Inadequate ventilation. 6. Trip and fall injury. 5. Supervisor and standby man to ensure record of all
6. Darkness inside the tank due persons working in confined spaces.
to lack of illumination. 6. Ensure good condition of tools.
7. Arrange shift work.
8. Provide access to shade at intervals.
9. Provide snacks and drinks in addition to cold water.
10. Ensure adequate ventilation by providing
ventures/exhaust fans.
11.Ensure adequate lighting by providing pneumatically
operated light fitting.
ACTIVITY - 31: ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING

1 Scaffolding 1. Improper manual handling. 1. Personal injuries. 2 5 HIGH 4 1. Train on proper manual lifting procedures.
erection 2. Fall of scaffolding materials. 2. Material damage. 2. Use only tested and certified equipment & lifting
3. Hitting. 3. Collapse of scaffolding and fall of tackles.
4.Defective lifting equipment / persons. 3. Erection only by experienced persons under
improper use. 5.Faulty erection. supervision of a competent person.
4. Daily inspection and certification by competent
person.
5. PTW in place.
47

2 Working on 1. Defective scaffolding. 1. Injury due to fall. 1 5 HIGH 4 1. Daily inspection & certification by competent
scaffolding 2. Improper use. person.
3. Faulty access to platform. 2. Training & supervision.
4. Inadequate size of platform. 3. Provide access (Ladders or Stairs_ as per
5. Overloading. specification.
6. Faulty / unguarded access 4. Adequate size as per job requirement.
ladder/stairs 5. No overloading permitted.
5. Only minimum number of persons allowed to work at
a time.
3 Dismantling 1. Fall of persons. 1. Fatality / injury. 1 5 HIGH 4 1. Follow dismantling procedures.

scaffolding 2. Fall of scaffolding materials. 2. Do not allow persons to be under the scaffolding
3. Fall of hand tools (hammer structure.
etc.) 3. Use PPEs (helmet, gloves)
4. Keep tools in proper holder.
ACTIVITY - 32: STRUCTURAL WORKS

1 Structural works 1. Personal negligence and 1. Can cause injury or casualty. 4 5 HIGH 4 1. Do not take rest inside rooms built for welding
danger of fall. machines or electrical distribution system.
2. Lifting / slipping of material 2. Avoid walking on beams at height.
3. Wear helmet with chin strap and full body harness
while working at height.
4. Use hand gloves and goggles during grinding
operations.
5. Cover or mark the sharp and projected edges.
6. Do not stand within the operation radius of cranes.
7. Do not stand under the lifted load.
8. Stack properly all the materials .Avoid slippage
during handling.
9. Control longer pieces lifted by cranes from both
ends with guidelines.
10. Remove loose materials from height.
11. Ensure tightening of all nuts & bolts.
48

ACTIVITY - 33: PIPELINE WORKS
1 Pipe laying 1. Erection/ lowering failure. 1. Can cause injury. 4 5 HIGH 4 1. Do not stand under the lifted load.
2. Others 2. Can cause injury. 2. Do not allow any person to come within the radii of
the side boom handling pipes.
3. Check the load carrying capacity of the lifting tools
and tackles.
4. Use safe Load Indicators.
5. Use appropriate PPEs.
6. Wear gum boots in marshy areas.
7. Allow only one person to perform signaling
operations while lowering the pipes.
8. Provide night caps on pipes.
9. Provide end covers on pipes for stoppage of pigs
while testing / cleaning operations.
ACTIVITY - 34: WORKING IN HOT ENVIRONMENT

1 1. Working in hot 1. Heat stress due to failure of 1. Heat ailments such as heat 2 4 MODERATE 3 1. Drink plenty of cold water.
environment. thermo-regulatory system of the exhausting, heat cramps and heat 2. Intermittent rest under shades.
2. Hot work such body. stroke. 3. Eating more vegetables and fruit items.
as welding, cutting, 2. Dehydration due to excess 4. Provide shade for work in static posture (welding).
heating, cooking, loss of body fluids. 5. Appropriate PPE to protect body against direct
etc. exposure to heat or hot sun.
ACTIVITY - 35: WORKING IN DUSTY ENVIRONMENT

1 Working in dust 1. Dust (Inhalation and striking 1. Lung disorders (silicosis) and eye 5 1 MODERATE 3 1. Sprinkle water to suppress dust generation wherever
the eye) injury. possible.
2. Use PPE (dust mask, goggles)
49

ACTIVITY - 36: WORKING DURING NATURAL CALAMITIES
1 Working / driving 1. Flood. 1. Drowning and washing away in 1 5 HIGH 4 1. Do not go into flood.
during natural 2. Fog. flood water. 2. No driving of vehicles in fast flowing water.
calamities. 3. Storm / high wind. 2. Injury /fatality due to hitting or 3. Ascertain the depth of water and the firmness of the
vehicle accident. road surface.
3. Injury due to collapse of buildings. 4. Keep on elevated terrain till flood subsides.
5. Vehicle /equipment movements only in clear vision.
6. Drive slowly with head lights and wipers on.
7. Sufficient anchoring of office cabins.
8. Outside doors fitted with auto hinges.
ACTIVITY - 37: STAY IN CAMPS

1 Staying in 1. Biological hazards (Malarial 1. Ill health. 2 4 MODERATE 3 1. Prompt disposal of wastes, concealment of
residential camps mosquitoes, contaminated water drainage.
/ food stuff) 2. Use of insecticides.
3. Ventilation in living accommodation.
4. Keeping food wastes in garbage bags/closed
buckets and prompt disposal to the food waste to
dump yard as per Waste Management Plan.
5. Dead slow driving in camp premises.
6. No night driving.
7. Extremely cautious against crossing of stray
animals.
8. Do not cause harm to any livestock.
9. Observe warning signals on roads against stray
animals.
50

ACTIVITY - 38: SLIPS, TRIPS AND FALLS AT WORK PLACE.
1 Moving in the work 1. Timbering blocks, wooden 1. Bodily injury due to fall of persons , 3 4 MODERATE 3 1. Remove all timber blocks, planks, pipe pieces etc
area. planks, steel rod bits. fall of heavy objects, tools etc. immediately after use to the designated place.
2. Pipe pieces. 2. Hitting on overhead projections. 2. Do not keep objects / tools etc at heights without
3. Protruding bolts on concrete safe containment against fall.
foundations of pipe supports. 3. Provide barricading with warning tags.
4. Paint tins, polythene papers, 4. Provide plastic/soft material cap to projecting pipes
electric cable/wire insulations, and warning tags to caution the workers.
steel wire insulations, steel wire 5. Maintain good house keeping by frequent
cuttings, tools & tool boxes. appraisals, supervision, inspection, audit and follow
5. Overhead projection of pipes. up.
Plant & Machinery

ACTIVITY - 39: FIRE PREVENTION AND PROTECTION
1 Fire prevention 1. Small fires can become big 1. Cause burn injuries and may prove 3 4 HIGH 4 1. In case a fire breaks out, press fire alarm system
and protection ones and may spread to the fatal. and shout "Fire, Fire".
surroundings areas. 2. Complete extinguishment of fire 2. Keep buckets full of sand and water / fire
2. Improper selection of Fire may not be possible. extinguishers in all hazardous locations.
extinguishers. 3. Can cause electrocution 3. Confine smoking to 'Smoking Zones' only.
3. Short circuiting of electrical 4. Train people for using specific type of fire
system. equipments under different classes of fire.
5.Maintain good house keeping and first -aid boxes.
7. Don't obstruct access to fire extinguishers.
51

ACTIVITY - 40: LAYING ELECTRICAL CABLES
1 Laying out 1. Unstable Cable drum. 1. Fatality / service injury due to fall of 4 5 HIGH 4 1. Cable shall be handled by experienced persons.
electrical cables 2. Wrong position of jack. cable drum or jack. 2. Adopt proper procedure.
(Cable drum 3. Inadequate jack / spindle. 2. Injury by hitting / caught in. 3. Use only tested and certified jack and spindle.
handling) 4. Defective jack / spindle. 3. Finger injury due to trapping 4. Keep fingers away from nip points.
5. Rotating parts. between drum / rollers. 5. Use hand gloves.
6. Drum rollers. 4. Serious injury due to slip & fall of 6. Tool box meeting.
7. Pulling in wrong posture. cable. 7. Proper position.
8. Open trench. 5. Loss of cable. 8. Trained person.
9. Theft. 9. Use cable roller.
10. Planning
11. Keep cable-laid trenches backfilled before leaving
site.
ACTIVITY - 41: POLE ERECTION

1 Loading / off 1. Improper lifting. 1. Serious injury. 3 4 MODERATE 3 1. Banks man.
loading poles. 2. Defective lifting tackles / 2. Fall of poles. 2. Experienced riggers.
equipment. 3. Damage to existing facility. 3. Deploy caged truck.
3. Open platform truck. 4. Use guide rope.
2 1. Pole hole 1. Rotating parts. 1. Injury due to rotating parts. 3 4 MODERATE 3 1. Deploy approved rig.
drilling. 2. Open drilled holes. 2. Injury due to fall of men & stray 2. Take care of rotating parts.
animals. 3. Cover all drilled holes.
3 Erection of poles 1. Live lines nearby. 1. Electric shock. 3 4 MODERATE 3 1. Keep safe distance.
2. Improper lifting & positioning 2. Injury due to fall of poles. 2. Close supervision.
of poles. 3. Trapping of hand / leg. 3. Avoid lifting of poles during heavy wind.
3. Loose soil. 4. Electric shock. 4. Approved equipment & tackles.
4. Live lines nearby. 5. Accident / injury due to lack of 5. Provide firm footing to equipment.
vision. 6. Keep away from OH line.
7. Use guide rope.
8. Face protection.
52

ACTIVITY - 42: PASSAGE UNDERNEATH OVERHEAD LINES.
1 Transportation of 1. Excess height can contact 1. Fatal electric shock. 2 5 HIGH 4 1. PTW.
equipment with overhead lines. 2. Damage to equipment. 2. Erect goal post.
exceeding 5m 3. Restrict passage.
height 4. Use inspected & approved lifting equipments &
tackles.
ACTIVITY - 43: WORKING NEAR OVERHEAD LINES

1 Working near 1. Live lines. 1. Electrocution (fatality / severe 2 5 HIGH 4 1. PTW in place.
overhead lines. injury) 2. Use guide rope for lifting load.
2. Damage to equipment and 3. Avoid working if lightning threat is suspected.
property. 4. Work area shall be clearly identified before start of
3. Fire / Explosion. work.
ACTIVITY - 44: ELECTRICAL INSTALLATION AND

USAGE
1 Electrical 1. Short circuiting. 1. Can cause Electrocution or Fire. 4 5 HIGH 4 1. Use rubberized hand gloves and other PPE.
installation works 2. Overloading of Electrical 2. Bursting of system can occur which 2. Don’t lay wires above ground or under carpets,
System leads to fire mats or door ways. Lay cables overhead or buried.
3. Allow only licensed electricians to perform on
electrical facilities.
4. Use only approved and insulated wires or cables.
5. Don't place bare wire ends in a sockets. Use
Plug tops.
6. Ensure earthing of all machines and equipments.
7. Do not use damaged cords and avoid temporary
connections.
53

ACTIVITY - 45: DENTING WORK
1 Washing vehicle 1. Fall of vehicle from 1. Equipment damage. 1 5 HIGH 4 1. Only trained persons should operate pneumatic
before denting pneumatic lifting jack. 2. Eye and body injury lifting jack.
work 2. Mishandling water hoses. 2. Washing hose must be handled carefully.
3. High pressure water jets must not be aimed towards
any person or delicate instruments.
2 Parking vehicles 1. Inadvertent movement of 1. Physical injury . 1 5 HIGH 4 1. Arrest all wheels with chocks
for job vehicle 2. Equipment damage. 2. Apply hand brakes
3. Loss of material. 3. Remove ignition key and remove battery terminals.
3 Heating parts / 1. Flying object. 1. Physical injury . 2 4 MODERATE 3 1. Keep fire extinguisher ready.
Removal of parts 2. Fire & explosion. 2. Burn injury 2. Wear safety shoes, safety helmet, goggles, gloves
& leather apron.
3. Select appropriate denting tools in good condition.
4. Gas cylinder should be sound one and fitted with
calibrated pressure gauge and color coded hoses &
provided with flash back arrestors.
4 Attending denting 1. Fall from heights. 1. Physical injury. 1 5 HIGH 4 1. Precautions against falling from height to be taken.
work 2. Fall of materials. 2. Hearing loss. 2. Use ear plugs to prevent damage to ears.
3. Flying of materials. 3. Burn injury. 3. Denter should ensure that there is no electrical
4. Flying tools. circuits, fuel lines & any other inflammable
5. Defective and improper tools. components at & around working area.
6. Noise 4. Proper supervision before starting the work.
7. Fire 5. Wherever possible detachable parts are to be
taken out separately and then do the welding.
5 Repair of fuel 1. Fire / explosion 1. Personal injury. 1 5 HIGH 4 1. Remove the fuel tank & keep it separately.
tanks underneath 2. Equipment damage 2. Drain the fuel & clean the tank.
the vehicle 3. Flush with sufficient quantity of water.
4. Gas testing.
5. Keep appropriate fire extinguisher.
54

ACTIVITY - 46: DRIVING / OPERATING VEHICLES & EQUIPMENTS
1 Driving /operating 1. Lack of knowledge and skill. 1. Fatality / injury. 2 5 HIGH 4 1. Only authorized persons to be deployed for driving /
vehicles/ 2. Untrained drivers / operators. 2. Loss of property / material. equipment operation.
equipment 3. Defective vehicles / 3. Damage to equipment. 2. Training / refresher training to drivers / operators.
equipments. 3. Use of appropriate vehicles /equipments.
4. Over speed / overload. 4. Inspection & supervision.
5. Provide banks men as appropriate.
2 Driving on graded 1. Loose surface, erosion, pot 1. Injury / fatalities due to accidents. 1 5 HIGH 4 1. Provide speed limiters.
roads holes. 2. Use tyres with a minimum of 2 mm tread.
3. Drive with dipped headlights and high intensity
lights on.
3 Speed driving 1. Crossing the speed limits 1. Personnel injury 3 4 HIGH 4 1. Obey speed limits and traffic rules strictly.
(Rash driving) 2. Always expect the unexpected and be a defensive
driver.
3. Use seat belts/ helmets.
4. Blow horn at intersections and during overtaking
operations.
5. Maintain the vehicle in good condition.
6. Do not overtake on curves , bridges and slopes.
4 Driving in adverse 1. Adverse weather condition. 1. Personnel injury. 4 5 HIGH 4 1. Read the road ahead and drive to the left.
condition 2. Falling objects/ Mechanical 2. May prove fatal 2. Keep the wind screen and lights clean .
failure 3. Do not turn at speed.
4. Recognize the hazard, understand the defense and
act correctly in time.
5. Ensure effective braking system, adequate visibility
for the drivers, reverse horn.
6. Proper maintenance of the vehicle as per
manufacturer's instructions.
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5 Drunken Driving 1. Consuming alcohol before and 1. Accident 4 5 HIGH 4 1. Alcohol and driving do not mix well. Either choose
during the driving operation 2. Personal injury alcohol or driving.
2. If you have a choice between hitting a fixed object
or an on-coming vehicle ,hit the fixed object.
3. Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
4. Do not force the driver to drive fast and round the
clock.
5. Do not day dream while driving.
ACTIVITY - 47: PARKING OF VEHICLES IN PARKING AREA

1 Vehicle parking in 1. Improper parking. 1. Rolling of vehicle resulting in 1 4 MODERATE 3 1. Follow parking procedure.
designated area 2. Uneven surface. fatality / injury. 2. Level ground for parking.
3. Defective hand brake. 2. Damage to vehicle / properties / 3. Proper Hand brake.
4. Absence of wheel choke. live facilities nearby. 4. Wheel chokes in position.
5. Non / Partial application of 5. Gear engagement.
hand brake.
ACTIVITY - 48: EMERGENCY STARTING / JUMP STARTING

1 Identify the break 1. Break down 1. Fatigue 3 2 LOW 2 1. Find out make, type and capacity of battery &
down vehicle vehicle broke down enroute.
2 Selecting the right 1. Acid splash. 1. Acid burn. 1 5 HIGH 4 1. Ensure the vehicle in neutral gear.
battery, heavy duty 2. Fire 2. Burn injury 2. Select a similar type of battery with the same volt &
cable, clamp tools capacity.
etc. 3. Select appropriate tools to be taken for the job.
4. Choke all the wheels.
5. Deploy a competent electrician to do the job.
3 Parking vehicle. 1. Movement of vehicle 1. Physical injury. 2 4 MODERATE 3 1. Park the vehicle in an appropriate position so that
2. Vehicle damage booster battery can be connected.
2. chock the 4 wheels of both the vehicles
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4 Connecting & 1. Fire 1. Acid burn injury 2 5 HIGH 4 1. Put the vehicle gear in the neutral & ensure it.
starting with 2. Acid splash 2. Connect booster battery +ve & -ve terminals
booster battery corresponding with the stalled vehicle.
3. Insert ignition key to start the engine &check the
instruments & controls.
4. Direct the vehicles to workshop for changing the
battery.
ACTIVITY - 49: HANDLING BATTERY

1 Remove old / 1. Inadvertent movement of 1. Physical injury . 2 5 HIGH 4 1. Make sure that front and rear tyres are chocked.
discharged battery vehicle . 2. Fire burns. 2. Switch off & take out ignition key.
from vehicle 2. Spark. 3. Acid burns. 3. Trained persons are to be deployed for removal of
3. Fire batteries.
4. Wear gloves,googles, safety shoes, etc.
5. Remove terminal first , then +ve terminal to
prevent spark-up.
2 Transportation of 1. Manual handling 1. Physical injury. 2 4 MODERATE 3 1. Adopt proper method of manual handling.
battery from store / 2. Acid burns 2. Use the service of required persons to handle
vehicle to battery heavy battery.
charging room. 3. Avoid contact with battery acid.
3 Filling the battery 1. Acid splash. 1. Acid burns. 1 5 HIGH 4 1. Use battery trolley. Place the battery slowly & push
with sulphuric acid 2. Explosion. 2. Explosion due to emission of it to charge room.
electrolyte. 3. Floor corrosion flammable hydrogen. 2. Flame proof lights & fire proof exhaust flame are to
3. Physical injury be provided in the room .
3. Exhaust fan to be "ON"
4. An emergency eye wash & emergency shower to
be kept ready.
5. Wear PVC apron, acid gloves, mask & goggles.
6. Use an acid filling pump to fill acid form the
container.
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7. Remove the vent plug and fill acid to the
recommended level, close the plug.
8. Rinse & clean the pumps with water and mild alkali
if available.
9. Use acid resistant tiles for acid handling areas.
10. Display MSDS of Sulphuric Acid electrolyte
4 Charging the 1. Fire hazard . 1. Physical injury. 1 5 HIGH 4 1. Wash the battery before placing it to change bed.
battery 2. Explosion hazard. 2. Material hazard . 2. Keep the battery level on charging platform and
2. Electric shock 3. Fatal. close the cap.
3. Inspect insulation cables and tension of clips.
4. Smoking, naked flames shall be prohibited within
the radius of 3m from the battery charging facility.
5. Adequate ventilation for quick dispersion of any
flammable hydrogen gas.
6. Charger power supply shall be disconnected prior
to connecting or disconnecting batteries.
7. All battery cell covers or plugs shall be removed
during charging and not replaced until all "bubbling"
has stopped.
8. Keep DCP fire extinguisher.
9. Use neutralizer (banking soda) for spilled acid.
10. Select correct voltage & current.
11. Keep it on charging up to the required standard.
12. Finally after total electrical disconnection flush the
floor with water.
5 Transportation of 1. Manual handling. 1. Physical injury. 2 5 HIGH 4 1. Adopt proper method of manual handling.
charged battery 2. Spark. 2. Acid burns 2. Use the service of required persons to handle
from charging 3. Fire. 3. Material hazard . heavy battery.
room to vehicle /
store.
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6 Refitting the 1. Chemical splash. 1. Acid burns. 2 5 HIGH 4 1. Clean the battery filling area.
battery from 2. Fall of battery . 2. Physical injury . 2. Lift the battery with others help.
charging room to Wrong terminal connection 3. Loss of material. 3. Fit clamps & bolts properly & tighten.
vehicle / store. 4. Vehicle damage. 3. Wear PPEs.
5. Discharged of battery. 4. chock the wheels.
5. First connect +ve terminal, then -ve terminal
7 Checking 1. Short circuit 1. Electric shock 2 4 MODERATE 3 1. Insert the ignition key and start the engine.
performance of 2. Observe charging & functioning of all electrical
battery. indicators & instruments panel indicators.
3. Close the bonnet & inform supervisor / equipment
engineer for final check up.
ACTIVITY - 50: OPERATION OF COMPACTOR

1 1. Starting by 1. Inadvertent contact with 1. Accidents. 2 4 MODERATE 3 1. Pull the string gently avoiding contact or hit against
pulling up with vibrator. 2. Damage. compactor or nearby personal.
string. 2. Rotating parts. 2. Guarding.
2. Running 3. Fall. 3. Hold firm and move slowly.
compactor
ACTIVITY - 51: OPERATION OF CRANE

1 Operation of Power 1. Inadvertent movement of 1. Accidents. 1 5 HIGH 4 1. Make sure PTO levers are in neutral position
Take Off (PTO) crane 2. Damage.
2 Positioning 1.Outriggers can sink in soft 1. Lifting of vehicle. 1 5 HIGH 4 1. Crane must be set on firm ground. On soft ground
outrigger. ground. 2. Tilting of vehicle. place strong wooden blocks or steel plates on ground
2. Improper extinction of the 3. Physical injury. and set outriggers on them.
outriggers. 4. Equipment damage. 2. Extend the outrigger beam fully as far as possible
3. Improper locking of 5. Material damage. during operation.
outriggers. 3. Be sure to lock the outrigger beams with lock pins.
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3 Locking operation. 1. Side loading or dragging of 1. Cause serious damage to 1 5 HIGH 4 1. Avoid side looking or dragging loads.
loads will exert extra load on equipment . 2. Strict adherence to SWL.
crane. 2. Crane becomes unstable & causes 3. Ensure crane is installed with safety limits.
2. Excess load. accident. 4. Move the levers in a slow manner.
3. Abrupt load. 3. Electrocution 5. Attention on operation.
4. Careless 6. Do not allow workers to stand within the working
radius.
4 Inspection of winch 1. Damaged or less turns of 1. Cause serious accidents 1 5 HIGH 4 1. Inspect rope for any damage or twist and replace in
rope. winch rope. case of any damage.
5 Travelling 1.Travelling with lifted load. 2. 1. Instability . 2 4 MODERATE 3 1. While travelling, disengage PTO.
Travelling with engaged PTO. 2. Causes serious accidents
6 Signals 1. Improper signs 1.Leads to confusion and accidents. 2 4 MODERATE 3 1. Competent banks man to be detailed for signals.
ACTIVITY - 52: OPERATION OF FORKLIFT

1 Loading Forklift 1. Careless operation 1. Can lead to accidents. 2 4 MODERATE 3 1. Do not allow anyone to stand or walk under the
elevated portion whether it is empty or loaded.
2 Overloading 1. Overloading 1. Equipment damage. 2 4 MODERATE 3 1. Check the load chart for load weight & load centre
Forklift 2. Physical injury information.
2. Always pick up loads as close to weight centre as
possible to avoid imbalance
3 Tip over of lift truck 1. Tip over 1. Leads to fatal accidents. 2 5 HIGH 4 1. Ensure emergency brake system (wherever
2. Equipment damage. applicable) is working properly.
2. Ensure seat belt is fastened.
3. When trucks begins to tip, “Do not attempt to jump
clear". Hold on to the steering wheel with both the
hands.
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4 Operation 1. Careless operation. 1. Careless operation can lead to 2 4 MODERATE 3 1. A trained operator only must be authorized to drive.
accident. 2. Avoid sudden starts, stops or turns, slow down for
2. Overturn turns & on uneven turn may be greater than when
travelling with load.
3. Use special care when operation on slopes. Travel
slowly and do not angle across or turn.
4. While ascending or descending slopes, drive the lift
truck with the load facing up grade.
5. When filling the tank with fuel or recharging the
battery, stop the engine.
6. Before leaving, be sure that forks or attachments
are lowered, gears in neutral and hand brakes applied
& key turned off & kept it under safe custody.
7. Avoid parking on a slope.
ACTIVITY - 53: OPERATION OF VIBRATOR

1 Starting by pulling 1. Inadvertent contact with 1. Injury. 2 4 MODERATE 3 1. Pull the string gently avoiding contact or hit against
up with string vibrator. 2. Contact with body. vibtator or nearby personnel.
2. Rotating parts. 3. Damage. 2. Guarding.
Kick back of hose. 4. Burn hazard. 3. Hold the hose firm while vibration is in use.
3. Cement splash. 4. Keep in safe place.
4. Fall of vibrator into 5. Keep away from naked flames.
excavation concreting location. 6. Keep DCP Fire Extinguisher ready.
5. Fire hazard
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ACTIVITY - 54: REMOVAL AND REFITTING OF GEAR BOX
1 Cleaning the 1. Slip hazard. 1. Physical injury. 2 4 MODERATE 3 1. Person cleaning should wear protective clothes like
vehicle for removal 2. Injury due to high pressure 2. Burn injury. gum boots, face shield, hand gloves & helmet.
of gear box. water hose. 3. Vehicle damage 2. Clear the floor from oil and grease.
3. Hit hazard. 3. Vehicle is to be parked on level ground with all four
4. Vehicle can roll. wheel chokes.
5. Hot surface. 4. First make the pressure hose straight & hold the
spray nozzle in hand away from self & others.
5. Make sure that the washing is not done on hot
surface.
2 Parking vehicle for 1. Vehicle rolling of. 1. Physical injury. 2 4 MODERATE 3 1. Arrest all wheels with chokes, apply hand brake,
the job. 2. Vehicle under a live 2. Vehicle damage. remove ignition key & remove battery terminal.
mechanism 3. Material damage. 2. Put the caution boards indicating off road.
3. Select correct & good tool for specific job.
4. Authorized trolley jack by competent person should
be used.
3 Removal of 1. Material falling. 1. Damage to the parts. 2 4 MODERATE 3 1. Deploy a competent / experienced workman for this
propeller shaft 2. Handling hazards. 2. Physical injury work.
2. Use trolley jack for removal of propeller shaft.
4 Removal of gear 1. Tilting & falling of gear box. 1. Damage to engine. 2 4 MODERATE 3 1. Use inspected / authorized trolley.
box 2. Physical injury. 2. After unloading, tie the gear box with chain to jam
platform to avoid the tilting and falling.
3. Pull out the jack outside vehicle and remove the
gear box to working place.
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5 Re-fixing of gear 1. Material handling. 1. Back strain. 2 4 MODERATE 3 1. Use inspected or authorized trolleys.
box 2. Falling. 2. Physical injury. 2. Deploy experienced persons.
3. Trapping of fingers. 3. Damage to engine. 3. Strict supervision.
4. Gently push the gear box under the vehicle to
position.
5. During transportation tie the parts with the trolley
jacks.
6. Re-check all nuts & bolts of gear box, fly wheel
housing, gear shaft mechanism.
ACTIVITY - 55: CHANGING OF ALTERNATOR

1 Prepare a vehicle 1. Rolling of vehicle. 1. Physical injury . 2 4 MODERATE 3 1. Park the vehicle on even and hard surface.
for replacing 2. Hit. 2. Vehicle injury 2. Choke all the four wheels.
alternator. 3. Apply hand brake.
4. Remove ignition key.
5. Deploy a skilled electrician for the work.
2 Removing of 1. Manual handling . 1. Physical injury. 2 4 MODERATE 3 1. Disconnect battery terminal, - ve terminal first &
alternator. 2. Sparking 2. Vehicle damage. then + ve terminal.
3. Material damage. 2. Use right tools.
3. Remove belt & alternator.
3 Disassembly & 1. Material handling. 1. Personal injury. 1 4 MODERATE 3 1. Use proper, goods tools.
assembly of 2. Fire hazard. 2. Vehicle damage. 2. Do the work with trained person.
alternator. 3. Use rubber hand gloves, while using cleaning
components.
4 Testing of 1. Nip hazard. 1. Physical injury. 1 4 MODERATE 3 1. Fit the alternator correctly with motor for testing .
Alternator 2. Electrical shock. 2. Fire causes damage to materials. 2. Check the correct connection of terminals.
3. Fire hazard
5 Fitting alternator. 1. Hit against short circuit . 1. Head injury. 2 4 MODERATE 3 1. Fix alternator properly.
2. Fire 2. Electrical shock. 2. Check the correct terminals connections.
3. Material loss. 3. Cross check the alternator function in presence of
electrician.
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ACTIVITY - 56: CHANGING OF HEAVY VEHICLE WHEEL
1 Parking vehicle for 1. Rolling vehicle. 1.Personal injury. 2. 2 4 MODERATE 3 1. Park the vehicle on an even, hard ground without
removal of tyre. Vehicle damage. obstruction.
2. Barricade vehicle boarder.
3. Prove wooden chock on 4 wheels and apply hand
brake.
2 Handling tools. 1. Slip. 1. Personal injury . 3 4 MODERATE 3 1. Select appropriate tools such as pneumatic box,
2. Hit. 2. Hit hazard spanner
3. Fall. 2. Test heavy duty trolley jack special lever and
4. Tier roll over pressure gauge.
3 Removal of wheel 1. Slip. 1. Personal injury . 1 4 MODERATE 3 1. Ensure that jack is of correct capacity.
from the vehicle 2. Hit. 2. Back sprain. 2. Check any oil / pressure leaks.
3. Fall. 3. Vehicle damage. 3. Provide wooden blocks after lifting to a suitable
4. Tyre roll over height.
4. Remove the wheel carefully.
5. Roll the tyres carefully with the help of others.
ACTIVITY - 57: TOWING OF DEFECTIVE VEHICLE

1 Assess the causes 1. Hot surfaces. 1. Physical injury. 1 4 MODERATE 3 1. During inspection do not touch any hot spots. Allow
of break down. 2. Inadvertent movements. 2. Heat burn. it to cool.
3. Hit hazard. 3. Vehicle damage / injury. 2. Choke all 4 wheels & apply the hand brake.
3. Retain the key of the vehicle before going out of
vehicle.
2 Prepare the vehicle 1. Defective movable parts. 1. Nip hazard. 1 4 MODERATE 3 1. If the transmission is found defective, remove the
for towing. 2. Improper towing devices / drive shaft connecting engine to gear box and gear
hook / chain. box to differential.
2. If steering system is damaged or axle assembly is
defective the vehicle is to be bought by towing.
3. Proper towing bar is to be used to tow a vehicle.
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3 Towing 1. Defective brake . 1. Accident. 2 5 HIGH 4 1. Ensure the vehicle to be towed is having enough
2. Defective hazard light. braking power.
3. Taking sharp turns and 2. Check the hazard light & horn is working.
sudden stops. 3. Avoid abrupt starting & stopping.
4. While towing, make sure that close contact is
maintained between both the drives.
5. Towing to be at low speed.
6. Make sure that the gear shift level on the vehicle to
be towed is in the neutral position.
7. Towing should be done straight as far as possible.
4 Towing 1. Improper method & 1. Vehicle accident. 2 5 HIGH 4 1. After deciding to carryout the tow, select the vehicle
equipment to carryout towing 2. Brake down of the towing vehicle. capacity to be towed.
2. Lack of pilot vehicle at the 2. Provide pilot vehicle if hazard light is not working.
rear in case of no hazard light 3. The towing vehicle should have the capacity of
from towed vehicle. lifting the broken down vehicle with valid test
3. Vehicle capacity & validity certificates.
certificate. 4. No passenger is to be carried out in the cabin at the
4. Carrying passengers inside rear of the towed vehicle.
the towed vehicle. 5. Towed vehicle is to be properly locked with the
towing to avoid collision on braking and turning.
6. Co- passenger should guide the drive of towing
vehicle.
ACTIVITY - 58: SPRAY PAINTING.

1 Washing 1. Slip hazard. 1. Physical injury. 3 4 LOW 3 1. Keep the area clean of loose materials like wooden
vehicle/equipment 2. Flying objects 2. Vehicle damage. skids, pipe pieces, etc.
thoroughly by 3. Vehicle roll. 3. Hot burns. 2. Clean the floor free of oil, grease and mud.
steam or high 4. High pressure hose. 4. Cuts. 3. Vehicle wheels to be checked.
pressure water. 5. Hot surface. 5. Material damage. 4. Seal the hydraulic and fuel tanks before washing.
6. Sharp corners. 5. Make sure that washing is not done on hot engine
7. Electrical contacts. or any other hot parts of vehicles.
7. Keep the water hose after winding in a proper place.
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2 Preliminary jobs 1. Vehicle roll over. 1. Physical injury. 2 4 MODERATE 3 1. Vehicle to be parked with four wheels choked with
before vehicles / 2. Lack of space around the 2. Hit against. wooden pieces.
equipment vehicle. 3. Suffocation. 2. Enough space for movement & for escape during
painting. 3. Slip hazard. 4. Burn injury. emergency.
4. Health hazard due to 5. Dermatitis. 3. Proper ventilation by providing exhaust fans &
painting. 6. Electric shock. exhaust hoods.
5. Fire hazard. 4. Flame proof light fittings / exhaust fans.
6. Fall. 5. No smoking in the area.
7. Handling putty. 6. Available of fire extinguishers.

8. Dust. 7. No unauthorized entry into the painting area.
9. Electrical Hazard. 8. Approved electrical tools should be used.
10. High pressure hose. 9. Compressed air lines should be handled with care.
10. Use proper, approved scaffolds with platform &
hand rails.
3 Spray painting 1. Fire hazard. 1. Burn injury. 3 4 MODERATE 3 1. Cordon off the area and place sign boards.
2. Fall. 2. Physical injury. 2. Strictly no smoking.
3. High pressure air line. 3. Dermatitis. 3. Wear respiration protection.
4. Solvent contact with skin. 4. Pulmonary disorders. 4. Effective exhaust system.
5. Inhaling of paint vapors and 5. Compressed air hoses should be handled carefully.
dust. 6. Use authorized scaffolds for painting.
7. No unauthorized entry into this area.
ACTIVITY - 59: WIRE ROPE REPLACEMENT (CRANE)

1 Parking the crane 1. Inadvertent movement 1. Accident 3 4 MODERATE 3 1. Select open place, level area, hard surface away
2. Physical injury. from traffic.
3. Equipment damage 2. Barricade and keep warning signs.
3. Choke the tyre in front and back.
4. Extend all 4 outriggers & lower the hydraulic jacks.
5. Remove the ignition key.
2 Cleaning . 1. Slipping & Falling. 1. Personal injury. 1 4 MODERATE 3 1. Proper house keeping.
3 Tools. 1. Improper tools, broken / 1. Personal injury. 3 4 MODERATE 3 1. Special tools recommended by manufacturer to be
damage tools slipping can used.
cause severe injury.
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4 Shifting new rope 1. Toppling of forklift. 1. Personal injury. 2 4 MODERATE 3 1. Deploy only trained persons.
drum. 2. Machine damage. 2. Load to be handled with specified S.W.L of forklift.
3. Equipment damage. 3. S.W.L. to be tested & certified by competent
4. Personnel injury. persons.
5. Equipment damage. 4. Load shall not be lifted so high which obstructs the
vision.
5 Transportation of 1. Boom hits on object / 1. Personal injury. 3 4 MODERATE 3 1. Obstruction shall be checked before lowering.
drum to site by fork personal. 2. Material damage. 2. No personnel shall be present near the boom.
lift / crane truck. 2. Electrical contact. 3. Do not operate crane without outrigger / banks men.
3. Handling hazard.
6 Removal of 1. Entangling of wire rope. 1. Electrical shock. 2 4 MODERATE 3 1. Disconnect main switch & remove the ignition key.
damaged cable 2. Damage to equipment . 2. Wear safety helmets, goggles, shoes, gloves.
from drums. 3. Ensure no tension in the wire rope.
4. With proper banks men’s signal wire rope has to be
removed carefully.
5. Engine to be stopped after removal of wire rope.
6. Make sure rope is not under tension.
7 1. Dismantling of 1. Whip lashing. 1. Damage to equipment. 1 4 MODERATE 3 1. Tie the wire rope with nylon cord & tie to the nearby
wire rope from the 2. Personal injury. frame.
drum. 2. Safe drawing of cable out.
8 1. Assembly of 1. Handling hazard. 1. Personal injury. 1 4 MODERATE 3 1. Lift the cable drum with forklift or crane truck and
wire rope 2. Slip hazard. 2. Damage to machine. mount it on a proper rope drum stand.
3. Falling hazard. 2. Strict supervision.
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ACTIVITY - 60: HANDLING AND LIFTING EUIPMENTS (GENERAL)
1 Handling and lifting 1. Failure of load lifting and 1. Can cause accident and prove 3 4 HIGH 4 1. Avoid standing under the lifted load and within the
equipments moving equipment. fatal. operating radius of cranes.
2. Overloading of lifting 2. Can cause electrocution and fire 2. Check periodically oil, brakes, gears, horns and tire
equipments. pressures.
3. Overloading electrical wires 3. Check size and condition of all chain pulley blocks,
slings, U-clamps, D- shackles, wire ropes etc.
4. Allow crane to move only on hard, firm and leveled
ground .
5. Allow lifting slings as short as possible and check
gunny packing's at the friction points.
6. Do not allow crane to lift its boom while moving.
7. Install Safe Load Indicator.
8. Ensure load test certification by competent
authority.
9. Safe lifting capacity of winches written on them
shall be followed.
10. The max. safe working load shall be marked on all
the lifting equipments.
11. Check the weight of columns and other heavy
items painted on them and accordingly decide about
the crane capacity, boom and angle of erection .
12. Allow only trained operators and riggers during
crane operation.
13. Do not allow the boom or other parts of crane to
come within 3m reach of overhead HT cables.
14. Hook and load being lifted shall preferably remain
in full visibility of Riggers and Operators.
ACTIVITY - 61: BATCHING PLANT OPERATION

1 Moving parts of 1. Hit by machine to workers 1. Physical Injury 2 4 MODERATE 3 1. Proper enclosure of all moving parts of machines.
Batching Plant working nearby. 2. Only trained and experienced workmen should be
permitted for operation.
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2 Loading of cement 1. Health Hazard 1. Silicosis, Pneumonia, Headache 5 2 Low 2 1. Enclosure around input hopper of Batching plant, to
into hopper 2. Health hazard due to etc. contain cement dust spread.
generation of cement dust. 2. Eye irritation 2. Water sprinkling in the area
3. Use of Dust Masks and safety goggles.
3 Transporting of 1. Hit by Machine to the 1. Physical Injury 2 2 TOLERABLE 1 1. Deployment of Banks man
Materials workers. 2. Eye irritation 2. Trained drivers and workers
2. Health Hazard due to 3. Breathing problems 3. Use of PPEs (Dust mask and Safety Goggles)
generation of dust. 4. Water Spraying in the area.
4 Handling of Plastic 1. Crush of hands and fingers 1. Hand/Finger injury 2 3 TOLERABLE 1 1. Deploy trained workers
Drums between drums 2. Eye injury 2. Use PPEs, like hand gloves, safety goggles
2. Splash of chemicals
ACTIVITY - 62: CHIMNEY CONSTRUCTION

1 Lifting of Rebar 1. Material falling. 1. Physical Injury 2 4 MODERATE 3 1. Metallic Bucket for base support.
2. Handling hazards. 2. Limiting the weight and quantity of rebar’s being
3. Injury to persons working lifted to 500 Kg.
below 3. Proper tying with slings.
4. Barricading the area
5. Not allowing any one once pulling of the material
starts.
6. Using guide ropes
1. Material hitting worker 1. Physical Injury 2 4 MODERATE 3 1. Using Safety Belts with proper anchorage
engaged at the top elevation of 2. Using Guide Rope
Chimney. 3. Not too far reaching from the edge while trying to
pull the material at the landing.
1. Sling Breaking 1. Physical Injury 1 5 HIGH 4 1. Using certified tools and tackles.
2. Lifting Hooks/Clamps 2. Deploying Trained persons.
Breakage 3. Visual inspection before starting the operation by
3. Winch Machine Failure responsible persons
during lifting 4. Ensuring color code.
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2 Lifting of Concrete 1. Concrete Bucket Collapse. 1. Physical Injury 2 5 MODERATE 3 1. Using only Certified Bucket and Clamps
2. Material Damage (Fall of concrete 2. Shuttering down the Bucket opening properly
mix) before lifting.
3. Ensuring that no one stands below the load.
1. Sling Breaking 1. Physical Injury 2 5 MODERATE 3 1. Using only Certified Lifting Tools and Tackles
2. Winch machine failure 2. Material Damage 2. Winch Machine certified.
3. Inspection before start of the operations.
3 Passenger Car (Lift 1. Failure of Lifting Tools and 1. Physical Injury 1 5 HIGH 4 1. Certification of Winch machine and all Tools and
for movement of Tackles. Tackles.
workers to go up 2. Overloading of Lift Car 2. Display of Load and no. of persons to be carried.
and to come down) 3. Winch Machine Failure 3. Emergency communication
4. Power Failure 4. Manual Operation provision to come down in case
of power failure
5. Maintaining log book for persons coming and going
in the lift.
6. Provision of Guide rope with fall arresting devices - 2
Nos.
7. Emergency Buzzer or siren
8. Rope ladder with fall arresting device from top to
bottom of the chimney.
9. Trained operator
10. Prohibiting carrying of materials in passenger car.
4 Concreting 1. Fall of Workers, Chips, 1. Physical Injury 3 4 MODERATE 3 1. Use of Full body Harness with double lanyards.
Concrete lumps and Material 2. Material Damage 2. Barrication of inner and outer portion of slip farm.
falling from height 3. Fencing by safety nets to prevent men and debris
fall.
1. Fall of Concrete Hose pipe 1. Physical Injury 2 4 MODERATE 3 1. Inspection of Concrete Hose pipe prior to the job
and Hopper 2. Material Damage commencement.
2. Holding the Concrete pipe with guide ropes
3. Not allowing workers to stand below the line of
Concrete discharge hose pipe.
4. Use of PPEs, Safety Helmets and Safety goggles.
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5 Concrete Chipping 1. Hit by flying chips of 1. Physical Injury 5 2 LOW 2 1. Use of dust mask and safety goggles.
concrete. 2. Eye Injury 2. Restricting the entry of others into the area.
2. Hit / crush with hammer or 3. Damage to health due to inhalation 3. Working in upward wind direction.
other tools of chipped concrete dust
6 Flue cane and 1. Fall of Material ( Beams, 1. Physical Injury 2 5 HIGH 4 1. Deploy only trained persons.
Structure Erection cane, Tools etc.) 2. Property Damage 2. Use of Full body harness with double lanyard.
2. Fall of persons 3. Provision of safety nets to prevent men and debris
fall.
4. Presence of Supervisors all the time.
7 Welding and Gas 1. Electric Shock 1. Physical Injury 2 5 HIGH 4 1. Deploy only qualified Welders
Cutting 2. Fire/Explosion hazard 2. Eye irritation 2. Provision of Fire Extinguishers
3. Hit by objects 3. Breathing problems 3. House Keeping
4. Radiation 4. Loss of vision 4. Welding machine earthing and Welding return
5. Heat Stress 5. Burns earthing
6. Welding fumes 6. Property Damage 5. Provision of ELCB on the panel
6. Provision of Flash back arrestor and NRV both at
cylinder and end and with torch.
7. Use of PPEs like Welding shield, Welding goggles
etc.,
ACTIVITY - 63: GRIT BLASTING

1. Bursting of Air lines. 1. Physical Injury. 1. Enclosing the area
1 Grit Blasting 2. Hit by high pressure hose 2. Eye irritation. 5 3 EXTREME 5 2. Arranging compressor away at a distance
pipes. 3. Breathing problems 3. Testing and certification of Compressor, Air
3. Health hazard due to 4. Hearing problems Receiver, Hopper valves, blasting gun and associated
inhalation of grit dust. parts of hydraulic marching by competent person.
4. Noise 4. Provision of blasting hood with breathing air supply
(demand regulator) to the operator.
5. Inspecting the airline connections for proper
clamping daily before use.
6. Use of Ear plugs/muffs.
ACTIVITY - 64: PRECAST YARD OPERATIONS
1 Manual Bar
bending 1. Cut / Crush while bending 1. Physical Injury 2 3 LOW 2
1.
2.
Proper type of tools.
Deploy experienced Persons.
3. Use of hand gloves.
4. Concentration of the job, no horseplay.
71

2 Machine Bar 1. Unguarded / Improper Guard 1. Physical Injury. 3 3 LOW 2 1. Proper Guarding of the moving parts.
bending of the machine 2. Damage to the machine. 2. House keeping in the area.
2. Defective Machinery. 3. Shock. 3. Provision of emergency switch.
3. Electric shock. 4. Trained and experience persons.
5. Proper Earthing and daily inspection of electrical
connections.
5. Proper Insulation.
6. PPE usage.
3 Shuttering / 1. Unsafe / Improper Handling. 1. Physical Injury 3 3 LOW 2 1. Watch and Keep away from protruded nails.
Handling of 2. Protruded nails. 2. Eye injury. 2. Secure the shutters properly and rigidly.
Wooden planks 3. Poor Housekeeping. 3. Use Safety Shoes and Hand Gloves.
and supports. 4. Hit by hammer. 4. Maintain Housekeeping.
5. Flying nails. 5. Use Safety goggles.
6. Maintain hand tools like hammers and their handles
in good condition.
4 Cutting Wood to 1. Unauthorized use of cutting 1.Physical Injury 3 3 LOW 2 1. Deploy trained carpenter.
required size machine. 2. Electric Shock. 2. Unauthorized use shall be strictly prohibited.
2. Fall of tools & wood on foot. 3. Short Circuit. 3. Use of hand gloves & goggles.
3. Improper Electrical 4. Use of Plug tops.
connections. 5. Proper Insulation at joints.
5 Preparation of 1.Flying nails while hammering. 1.E y e injury. 3 4 MODERATE 3 1. Wear Safety goggles.
shuttering on 2.Use of loose hammer. 3. 2. Flying hammer hitting body parts. 2. Ensure that hammer handle is properly welded &
ground. Tripping hazard 3. Foot injury by spilled nails in the hammer is in good condition.
area. 3. Maintain good house keeping.
4. Carry Tools in boxes and collect nails in bins.
6 De shuttering and 1.Fall of shuttering. 2.Protruding 1. Physical Injury. 2 3 LOW 2 1.Deploy experienced workers.
de shoring nails 3.Loose nails on floor. 2. Maintain good house keeping in the area.
3. Collect remove nails in bins and stack shuttering
materials properly.
72
7 Loading & 1. Fall of loaded material. 1. Physical Injury. 1 5 HIGH 4 1. Follow lifting plan and procedure.
unloading of 2. Defective equipment. 2. Damage of equipment and 2. Use correct equipments and certified lifting tools.
precast materials 3. Failure of Lifting Tools and material. 3. Provide trained Rigger.
on tractors/ Trails. Tackles 4. Do not jump out from vehicle till clearance is
4. Overloading. obtained.
5. Carrying out lifting operations under complete
supervision.
6. Follow load chart.
7. Use platform/ladder for safe access.
8 Shifting of precast 1.Failure of Equipment. 1. Serious physical Injury. 1 5 HIGH 4 1. Follow lifting procedure.
beams with gantry 2. Failure of Lifting Tools and 2. Damage of materials. 2.Use correct equipment and certified lifting tools.
crane. Tackles. 3. Damaged of equipments. 3. Provide trained foreman/Rigger.
3. Persons working near the 4. Electric Shock and Short circuit. 4. Complete gantry to be tested by third party
moving crane. (competent person ).
4. Electrical short circuit. 5. Proper supervision.
6.Follow load chart.
7. Use platform/ladder for safe access.
8. Inspection of gantry and lifting tools and tackles,
everyday before commencement of operations as per
check list.
9 Moving in the work 1. Hit by wooden planks and 1. Physical injury due to fall of 3 4 MODERATE 3 1. Remove all planks, pipes pices etc. and stack
area. steel rods. persons, fall of heavy objects, tools properly.
2. Struck by protruding bolts. etc. 2. Do not keep objects/tools etc. at height/on the way.
3. Slip and trip hazard by Loose 2. Hitting of overhead protection. 3. Provide barricading with caution tags.
electrical cables laying on 4. Maintain good housekeeping.
ground.
10 Concreting REFER ACTIVITY - 4: CONCRETING
73

ACTIVITY - 65: FABRICATION YARD OPERATIONS
1 Grinding and 1. Absence of tool rest on 1. Eye / face injury 3 4 MODERATE 3 1. Use proper PPE. ( Face shield )
grinding wheel bench grinder. 2. Hand injury 2. Mount the tool rest on both sides.
replacing. 2. More gap between the wheel 3. Gap more than 3mm is unsafe.
and tool rest of bench grinder. 4. Use grinding wheel of correct size.
3. Improper/wrong size grinding 5. Training & instruction.
wheel. 6. Provide fire extinguisher.
4. Excess pressure on wheel. 7. Proper tightening of wheel.
5. Breakage of wheel. 8. Use of correct size spacer washers.
2 Working with 1. Damaged cable . 1. Electric shock. 3 4 MODERATE 3 1. Daily check up before start.
portable electric 2. Defective tool. 2. Spark/shock. 2. Replace defective tools.
tools 3. Loose components (wheel, 3. Physical injury. 3. Proper maintenance.
switch) 4. Training on proper use & care.
4. Excess pressure on tool. 5. Inspection and corrective action to follow correct
5. Improper handling. handling procedures.
6. Non use of PPE. 6. Use adequate PPE (Face shield/goggles, gloves)
3 Gas welding / 1. Backfiring. 1. Fatality / burn injury, fire / 2 5 HIGH 4 1. Work only after wearing PPE.
cutting / heating. 2. Splashing splinters. explosion. 2. Fit flash back arrestor and NRV on both cylinder
3. Gas leakage. 2. Gas leakage due to fall of cylinder outlets.
4. Wrong positioning of and damage of valves. 3. Use face shield and fire proof gloves.
cylinders. 4. Daily check up before start of work.
5. Presence of flammable 5. Keep cylinders in trolleys or chain to some firm
gases. structure to prevent fall.
6. Gas testing before start of work.
7. Employ competent and trained welder.
8. Provide windshield.
74

4 Arc welding 1. Radiation harmful to naked 1. Welder's cataract. 2 5 HIGH 4 1.Use welding shield / goggles.
eyes. 2. Burn injury. 2. Fireproof apron / gloves / screen.
2. Splinters / slag. 3. Lung ailments 3. Ventilation (local or exhaust if possible)
3.Toxic flames. 4. Electric shock. 4. Full-sleeved coverall and gloves.
4. Loose connections / Loss of 5. Fire / explosion. 5. Proper clamping system / material handling
insulation. 6. Asphyxiation. techniques.
5. Flammable gases. 6. Use shock proof boots and hand gloves.
6. Poor ventilation 7. Provide earthing to the plant.
8. Periodical gas testing.
9. Keep fire extinguisher (DCP/CO2) standby.
10. Adequate ventilation.
11. Training & instructions.
5 Material handling 1. Lack of co-ordination in 1. Back pain,sprain,etc. 3 4 MODERATE 3 1. Training & instructions.
(manual) group effort. 2. Body Injury 2. Use hand gloves/ packing materials.
2. Wrong body posture. 3. Remove protruding nails before handling.
3. Lifting error. 4. Use proper lifting devices for good grip.
4. Sharp 5. Fasten the item properly or use suitable packing /
edges/corners/projecting container.
parts/protruding nails.
5. Slippery materials.
6. Loose materials.
6 Material handling 1. Lack of knowledge / skills. 1. Body injury. 2 4 MODERATE 3 1. Only trained and approved operator shall be
with forklift / crane 2. Defective equipment. 2. Material losses. deployed for equipment operations.
etc. 3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent
4. Overloading. person before deployment.
3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banks men / rigger.
75
7 Transporting gas 1. Falling of cylinders 2. Gas leakage due to valve damage. 2 5 HIGH 4 1. Keep charged cylinder only.
cylinders: 2. Explosion 3. Human injury by fall of cylinder. 2. Keep vertically and tie with chain to a fixed
* Oxygen 4. Fire / body injury due to explosion structure.
* Acetylene. 3. Keep in specially fabricated cage to prevent fall.
* Argon. 4. Keep valve cap in position during transportation.
* Nitrogen. 5. Different types of gas cylinders not to be loaded in
* LPG. the same vehicle at a time.
6. Only authorized vehicle and specially trained driver
shall be engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked
independently on truck to prevent falling of one
cylinder while loading/unloading the other.
8 Laying out 1. Unstable Cable drum. 1. Body injury due to fall of cable 3 4 MODERATE 3 1. Cable shall be handled by experienced persons.
electrical cables 2. Wrong position of jack. drum or jack. 2. Adopt proper procedure.
(Cable drum 3. Inadequate jack / spindle. 2. Injury by hitting / caught in. 3. Use only tested and certified jack and spindle.
handling) 4. Rotating parts. 3. Finger injury due to trapping 4. Keep fingers away from nip points.
5. Drum rollers. between drum / rollers. 5. Use hand gloves.
6. Pulling in wrong posture. 6. Use cable roller.
7. Open trench. 7. Keep cable-laid trenches backfilled before leaving
site.
ACTIVITY - 66: LIFT OPERATION AT H.O.

1 Travelling by 1. Stoppage of Lift due to 1. Panic 2 3 LOW 2 1. Stay Cool.
Passenger Lift Power failure in between floors. 2. Physical problems due to 2. Raise Alarm by pressing the emergency button
from Lobby to all 2. Stoppage of Lift due to hypertension and anxiety provided in the lift car.
Floor technical problems in between 3. Cooperate with maintenance crew and rescue
floors. persons, in case of emergency.
3S 1. Physical Injury 2 5 HIGH 4 1. Maintenance of Lift is the responsibility of the

1. Fall of Lift from upper floors 2. Fatal Building Society.
due to snapping of Cables. 2. Society shall ensure periodic maintenance by
2. Fall of Lift due to Technical competent persons.
Problems in the driving motor. 3. Society shall ensure periodical visual inspection of
cables, car and winch.
4. Records shall be maintained for the maintenance.
76

ACTIVITY - 67: MENTAL WORKLOAD AT H.O.
1 Office Work 1. Working beyond normal work 1. Mental worry 2 3 LOW 2 1. Practice stress relief measures.
hours 2. Low morale 2. Take a break when feel like stressed.
2. Working under pressure 3. Anxiety/hyper tension 3. Conduct personality development trainings to give a
3. Work requiring 4. Irritation break from routine work.
concentration/attention 5. Demoralization
4. Failure to achieve desired 2. Physical problems due to
results. hypertension and anxiety
ACTIVITY - 68: USE OF VDU'S

1 Use of Computers 1. Improper seating. 1. Physical Problems like spondilytis. 2 3 LOW 2 1. Arrange height of the seat and back as per the
in Office 2. Distance from the monitor. 2. Vision Problems. guidelines.
3. Eye level. 3. Problems Limb joints. 2. Maintain min. 25 cms distance from the monitor and
4. Hands not positioned 4. Anxiety and Irritation. maintain eye level and Hands in line with forearms.
properly. 3. Keep mouse or key board comfortably not far away.
5. Feet not positioned properly. 4. Place feet firmly on the ground.
5. Ensure periodic medical checkup by Ophthalmist.
ACTIVITY - 69: ILLUMINATION IN H.O.

1 Office illumination 1. Insufficient illumination. 1. Gradual vision loss. 2 3 LOW 2 1. Maintain proper illumination in the work area,
2. Pathways, exits and stairs 2. Physical problems due to pathways, exits and in stair cases.
not properly illuminated. hypertension and anxiety. 2. Ensure localized illumination.
3. General illumination too low 3. Irritation. 3. Ensure general illumination levels at at least 20% of
compared to localized 4. Physical Injury. localized illumination level.
illumination. 4. Ensure proper maintenance of illumination systems.
5. Ensure comfort levels for general working.
6. Ensure periodical medical check-ups.
ACTIVITY - 70: VENTILATION IN H.O.

1 Working in H.O. 1. Inadequate ventilation 1. Reduction in Oxygen percentage in 2 3 LOW 2 1. Maintain the systems in good conditions.
2. Suffocation. the circulating air in the area. 2. Allow fresh and natural when systems are not in
3. High density of Occupants. 2. Breathing problems. working conditions.
4. Improper maintenance of 3. Inconvenient working atmosphere. 3. Do not congregate.
HVAC Systems.
77

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HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ANALYSIS (RISK)

SL. NO. ACITIVITY PAGE NO.

ACTIVITY – 15 USING ENGINE GENERATOR SET 37

ACTIVITY – 53 OPERATION OF VIBRATOR 61

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

3 Unloading blocks 1. Fall of blocks 1. Personnel injury 4 3 MODERATE 3 1. Safe handling

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 3: CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER.

ACTIVITY - 5: CONCRETE MIXTURE OPERATION

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 10: SHUTTERING AND SHORING

ACTIVITY - 11: WORK ON REBAR

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 15: USING ENGINE GENERATOR SET

ACTIVITY - 16: HANDLING OF PORTABLE ELECTRICAL TOOLS

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 18: GAS WELDING

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 20: WORKING IN CONFINED SPACE

ACTIVITY - 21: MATERIAL HANDLING (MANUAL)

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 23: WORK AT HEIGHTS

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 25 LOADING / UNLOADING ON TRUCK / TRAILER.

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 28: HANDLING OF GAS CYLINDERS

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 31: ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

3 Dismantling 1. Fall of persons. 1. Fatality / injury. 1 5 HIGH 4 1. Follow dismantling procedures.

ACTIVITY - 32: STRUCTURAL WORKS

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 34: WORKING IN HOT ENVIRONMENT

ACTIVITY - 35: WORKING IN DUSTY ENVIRONMENT

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 37: STAY IN CAMPS

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

Plant & Machinery

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

ACTIVITY - 41: POLE ERECTION

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 43: WORKING NEAR OVERHEAD LINES

ACTIVITY - 44: ELECTRICAL INSTALLATION AND

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 47: PARKING OF VEHICLES IN PARKING AREA

ACTIVITY - 48: EMERGENCY STARTING / JUMP STARTING

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

ACTIVITY - 49: HANDLING BATTERY

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES