Safety in Construction Industry: Chapter - 22

CHAPTER – 22
Safety in Construction Industry
THEME
1. Scope of Safety in Construction work 6.2.2 Cast-in-situ Concrete Structures

1.1 Basic Philosophy 6.2.3 Wall and Floor Openings
1.2 Parameters of Safety in Construction 6.2.4 Formwork and Slipforms
1.2.1 Studies, Statistics and Results 6.3 Structural Steel work and Equipment
1.2.2 Site Planning and Layout 6.4 Welding and Cutting Operations
1.2.3 Safe Access 6.5 Lifting Machinery and Equipment
1.2.4 Safety work Permit & Checklist 7. Underwater Works
1.2.5 Good Housekeeping 7.1 General Provisions
2. Statutory Provisions 7.2 Boats
3. Indian Standards 7.3 Rescue and Emergency Procedures
4. Construction Machinery 7.4 Well-sinking
4.1 Lifting Appliances and Gear 7.5 Cofferdam
4.2 Transport, Earth-moving and 7.6 Caissons
Material Handling Equipment 8. Demolition
4.3 Plant Machinery, Equipment and 8.1 Precautions Prior to Demolition
Hand Tools 8.2 Precautions During Demolition
5. Underground Works 9 Movement of Materials and Men
5.1 Excavation 10 Health and Welfare of Construction Works
5.2 Drilling, Loading and Blasting 10.1 Dust Hazards
5.3 Shoring and Underpinning 10.2 Noise & Vibration
5.4 Tunnelling and Shaft Sinking 10.3 Heat and Humidity
6. Aboveground Works 10.4 Other Hazards
6.1 Scaffolding, Ladders and Staircases 10.5 First-aid and Health Services
6.2 Structural Frames, Formwork and 10.6 Welfare
Concrete work 10.7 Accident Reports and Records
6.2.1 Erection and Dismantling of 10.8 Ergonomics
Steel and Prefabricated Structures
1 SCOPE OF SAFETY IN CONSTRUCTION WORK
1.1 Basic Philosophy : 03235213618
Construction activity is not only an oldest industry but also the largest one in many parts of the
world. It started with the basic human need 'shelter, home or dwelling house' and is ever expanding with
the growing population and their growing needs of residential and commercial buildings, shops, offices,
factories, roads, bridges, dams, railways, power transmission lines, communication lines, towers,
columns, chimneys, silos, oil and gas installations, air fields, hoists, lifts, many types of underground,
under-water and aboveground works and works of excavation, foundation, construction, alteration,
renovation, repair, maintenance, demolition, dismantling, erection, fabrication etc.
After agriculture, construction seems to be the second largest economic activity. If mining and
quarrying are considered as a part of or inclusive of construction industry, it becomes the largest of all
industrial activities. Some figures of the most advanced country, USA, are as under :
Fundamentals of Industrial Safety and Health 22- 1 Safety in Construction Industry

Table : 22.1 Deaths & Death Rates, USA :
1992 1993 1994 1995 1996

DEATHS
Agriculture 779 842 814 723 710
Mining, 175 169 177 156 150
Quarrying
Construction 889 895 1000 1043 1000
Manufacturing 707 698 734 638 610
Trans. & Pub. 767 753 819 822 750
Util.
Trade 415 450 492 451 460
Services 601 631 676 655 610
Govt. 586 528 534 523 510
DEATH RATES (per 1 lakh workers)
Agriculture 24 27 24 21 21
Mining, 25 28 30 26 25
Quarrying
Construction 15 15 16 16 15
Manufacturing 4 4 4 4 3
Trans. & Pub. 13 13 13 13 12
Util.
Trade 2 2 2 2 2
Services 2 2 2 2 1
Govt. 3 3 3 3 3
Source : Accident Facts, 1997, NSC, USA.
In our country reportability of construction accidents is not known. But following figures are
reproduced below from Indian Labour Statistics, 1991-93.
NIC Code 50 & 51 represents construction and construction activities and all India fatal accidents
in this industry are as under :
Year Fatal Accidents

1986 114
1987 141
1988 100
These figures are not reported for many years and from many States and many works. Therefore
this data is incomplete and misleading.
Table 22.1 makes it clear that the combined deaths and death rates of construction and mining
industries are more than even agriculture. Decrease during last years indicates that safety activities can
certainly decrease the accidents. This proves the scope and importance of safety in construction industry.
As per rough estimate about 2 lakh firms and more than 200 lakhs workers work in construction
industry in India. Thus mostly it is labour oriented and unorganised. Workers are mobile, mostly illiterate

and work on contract basis. They work under sun and rain, cold and wind and dust and sand. Their
working conditions are mostly unsafe, hazardous and unhygienic. Their workload is heavy and demands
heavy muscular work. Their work and workplaces are not of permanent nature and therefore not
governed by any law like the Factories Act. The Building and other Construction Workers Act 1996 and
the Rules 1998 have been passed and implemented in 2006. The overall working conditions of majority
of construction workers are, therefore miserable.
Basic philosophy to improve their working conditions is the safety philosophy. It should be
realised that construction is inherently hazardous industry, , contract based industry, demands heavy work
load, contributes high frequency and severity of accidents, less protected by law, movable and needs
continuous efforts to maintain safety at all levels. It may not be possible to completely eliminate the
hazards, but it is certainly possible to minimise them by enforcing certain safety precautions. The
working and service conditions of the workers need to be improved. Peculiarity of accidents is well
known. Falling from height, struck by falling body including landslide, material and equipment, striking
against object, falling on the flat or into pit, sump, gutter etc., occupational diseases of lung, skin,
locomotors and nervous system, electrical and pneumatic tools, unguarded machinery, heavy vehicles and
working without safety equipment are the major causes of accidents. Mechanization can eliminate some
manual work hazards. Work permit system, prompt supervision and first-aid, use of personal protective
equipment and proper tools, training and education and project safety committee are some of the remedial
measures.
Safety philosophy for construction work should be based on the following points:
1. Safety policy statement and strict adherence to it.

2. Safety cannot be delegated. It is a line function.
3. Safety is everybody's responsibility.
4. It is an integral part of all project activities.
5. Good planning and advice, and discussion with contractor and subcontractors are essential at
design or initial stage.
6. Safety ensures success with satisfaction.
7. Work permit system is desired for all hazardous works.
8. All construction accidents should be recorded, reported and investigated for the purpose of safety
and costing.
9. Standards, Codes and Statutory provisions must be followed. Safety manuals should be prepared
for contractors, workers and supervisors, and
10. Education, training and supervision for safe work methods and use of safe tools and equipment
play an important role. See Part I of Chapter-? also.
12. Parameters of Safety in Construction:
Peculiarities and parameters .governing safety in construction industry are, now, discussed in the
following paragraphs.
1.2.1 Studies, Statistics and Results :
Statistics and studies on construction accidents are not much available as factory accidents. This is
mainly because of no exclusive authority, late and poor administration, non report ability and no
complete compilation of such data.

In one study which lasted for 15 years, Levitt (1987) highlighted the hidden costs of construction
accidents. He concluded that these accident costs mostly exceeded the gross-profit of most of the firms in
construction industry. He also found that all managers who had good safety records do three things:
1. Motivate their subordinates to attend to safety.

2. Provide training for managers and workers at all levels, and
3. Insist that work is carefully planned.
Champoux et. Al. (1987) studied 357 accidents in construction industry and identified the higher
risk areas of work and orgnaisation as targets for prevention. High risk tasks are crucial to ergonomist
and all those working for safety in construction.
National Institute of Training for Industrial Engineering (NITIE), Bombay conducted a study
(1989) and after interviewing site engineers, safety officers and labourers on site, it was concluded that
the reasons for health and safety problems were -
1. The absence of safety rules and regulations.

2. The unorganised nature of work.
3. Almost total lack of any need for safety felt by engineers and contractors and
4. Absence of trade unions for welfare and health.
The main safety measures suggested were

1. Compulsory use of safety helmets.
2. Use of safety belts for working at heights greater than 1.5 m.
3. Provision of canvas around the scaffolding to prevent falling objects from striking people.
4. Good and tidy housekeeping.
5. Provision of proper tools and
6. Adequate training to new workers.
Occupational health diseases were studied by Englund, Triebig, Duivenbooden and Husmark
(1987). Diseases of the skin, locomotor, circulatory, respiratory and nervous system were noticed
amongst construction workers. A few occupations handling asbestos, showed respiratory cancer in
plumbers and insulators.
Fatal occupational injuries in Construction, by type of event or' exposure, in USA, 1995 are
reported as under (Accident Facts, 1997) :
Out of total 6210 fatal accidents in all occupations in 1995, 1043 i.e. 16.79% fatal accidents took
place in construction and comparatively it is the highest in this industry. Its causewise breakup is as
under:
Fall to lower level 324

Electric current . 163
Traffic accidents 117
Struck by object 104
Struck by vehicle, mobile equip. 079
Caught in or crushed in collapsing materials 052
Caught in or compressed by equipment or object 033
Others 171
Total 1043

One study of construction accidents in our country gives following figures.
Type of Accident Temporary Total Permanent Partial Permanent Total

Disablement % Disablement % Disablement %
Handling of Materials 24.3 20.9 5.6
Falls 18.1 16.2 15.9
Falling object 10.4 8.4 18.1
Machines 11.9 25.0 9.1
Vehicles 8.5 8.4 23.0
Hand Tools 8.1 7.8 1.1
Electricity 3.5 2.5 13.4
Others 15.2 10.8 13.8
Total 100 100 100
Following figures were 'published in Industrial Safety Chronicle, Oct-Dec, 1996, as ILO data for
Construction Sector :
Country Accident Rate per 1000 workers Fatality Rate per 1000 workers
Austria 142 25
France 125 30
Germany 120 16
Mauritius 70 15
Mexico 70 24
Spain 138 38
Sweden 48 9
United States 70 25
To compare with this. Accident Rates for the year 1992 and 1993, given by Construction Wing of
NPC (Nuclear Power Corporation, India) are reported as 10.05 and 12.06 respectively. This indicates that
our construction accidents are 5 to 14 times less than those of foreign (developed) countries.
Similarly Fatality Rates for 1992 and 1993, given by the same NPC, India are 0.124 and 0.120
respectively and again these figures when compared with ILO figures, indicate that fatal construction
accidents in our country are 75 to 320 times less-than those in western countries.
The reasons of this anomaly, as stated in the article are as under :
1. Gross under-reporting of accidents by Indian industry.

2. ILO figures include first aid injuries while ours are reportable (48 hours absence) accidents.
3. ILO figures are old when safety efforts in western countries were poor.
Now some figures of recent construction accidents in our country are given below.
37.5 °/ 32.5 ~ 12.5 °/ 07.5 °/ 10.0 °/ inn °/
Some 30000 workers were employed at one place in Gujarat constructing various plants during
1991 to 1997. The large civil construction and structural steelworks including fabrication and erection o
buildings were carried out through competent contractors and sub-contractors. Safety Officers and safety
supervisors were also employed exclusively for contract workers. Record of all accidents, reportable o

not reportable, was maintained, studied and used in further prevention of accidents. Its summary is a
under:
From March 1994 to July 1997, total fatalities were 39. Its cause-wise percentage break-up is as
under :
1. Struck by falling objects, structures, plant, 37.5%

mobile construction equipment etc.
2. Fall 32.5%
3. Electrical 12.5%
4. Traffic accidents 07.5%
5. Others 10.0%
Total 100%
Comparing above figures with the same causation figures of USA, UK, Germany, Sweden, Japan
and Canada (from Safety &: Health Journal of USA - 1994), it is deduced that, all over the world, t1ie
first two major causes of fatal accidents in construction activity are :
(1) Fall from height and

(2) Struck by falling objects.
Therefore safety work to eliminate these causes need first priority.
Statistics of nonfatal accidents of above mentioned construction during 1995 to 1997, gives
following figures :
1. Types of Accidents - Fall from heights 15 to 22%, struck by falling objects 13 to 33%, struck by
others 21 to 38%, Electric shock 2 to 7%.
2. Agency/ Activity - Material handling 27 to 41%, Work at height 14 to 21%, Hand/Power tools 10
to 12%, Fabrication & election 12 to 13%.
3. Body parts injured - Hand, Fingers & arms - 22 to 35%, Head & scalp - 16 to 18%, Foot &toe 12
to 15%, Leg & thigh 9 to 17%.
As a summary from various such records, general classification of hazards at construction can be
drawn as under :
Hazards at Construction :
1. Fall of Persons - Fall from height, fall through opening, collapse of scaffold, structure failure,
tripping.
Fall from height may be due to non-use or failure of safety belt, lack of proper access,
nonuse of proper ladder etc.
Fall through opening may be due to unguarded opening or poor guarding.
Collapse of scaffold may be due to its improper design, no toe board, no means of access.
Minimum dimensions are : Board width 6", thickness I" and guard rail height 30 to 36".
Tripping may be due to loose object/cables etc.
2. Fire : Due to welding, gas cutting, smoking, gas cylinders, scattered wooden material/ rubbish,
paints/thinners, temporary shed etc.
3. Electrocution : Electric shock, burns, damaged cable, no earthing, no ELCB, no use of 3 pin
plug/socket, work by non-qualified electrician etc. .

4. Material Handling : No training,- excessive weight lifting, improper or failure of lifting tackles,
slings etc.
5. Transport Accidents : Untrained driver, not obeying traffic rules, reversing without signalling,
over-speed, speed-breakers, poor brakes, poor lighting etc.
6. PPE : Not using helmet, safety shoes, hand gloves, safety belt, respirators etc.
7. Others : Noise, vibration, dust, gas, fumes, cave in, night work, overtime, intoxication etc.
This suggests the direction of accident prevention work in construction activity.
1.2.2 Site Planning and Layout :
In construction activities, scope of site selection is less though not zero. Mines are at fixed places
and cannot be shifted. Builders or organisers generally purchase the site where land is available at low
price and where .contractors and workers have to work. In a fixed factory premises, construction is to be
carried out in a limited space. In dense population, construction of high rise (multi-storeyed) building
needs working at height. Gutters and underground piping have fixed tracks available. Underwater work
has fixed destinations and long pipelines are passed through the shortest possible distance for economic
reasons. Therefore in a limited scope of site selection, planning and layout becomes most essential on .the
available site.
Refer part 6 and 7 of Chapter 7 for planning, design and layout.
First, plan for the whole and then for the detail. Plan site layout, plot layout and equipment layout
as per requirement. Alternate layouts should be prepared for selecting the best one. Process flow diagram
and stages or sequence of work should be decided. Each work should be subdivided in steps accounting
for safety precautions and responsibilities. Facilities for water, fire fighting, first-aid, tools and equipment
availability, roads, vehicle movement, parking, smoking booths, sanitary blocks, creche, canteen, control
room, safe entry, exit and escape route etc. should be properly planned. Topography, geology, weather,
environment, separation distances, service corridors, overhead work (pipe bridges, tanks, slabs etc.),
segregation etc. should also be considered. Special precautions should be encountered for working at
heights or depths (See Chapter 16).
Planning, layout and designing of steel structure, tall towers, metal tanks, vessels, reactors,
utilities, piping etc. need Hazop, hazard identification, risk and reliability assessment, strength and
stability criteria, inventory reduction, process safety, fail-safe design, emergency shut-down procedure
and emergency planning.
Appointment of safety and health personnel, trained supervisors and requirement of adequate
first-aid and fire fighting facilities and personal protective equipment should be considered at the stage of
planning and budgeting for safety at work.
1.2.3 Safe Access :
For the safety of workplaces and avoiding risk of injury to workers, safe means of access to and
egress from all workplaces should be provided, maintained and indicated where necessary.
Section 32 of the Factories Act requires that all floors, steps, stairs, passages and gangways' shall
be of sound construction and properly maintained and shall be kept free from obstructions and substances
likely to cause persons to slip and where it is necessary to ensure safety, steps, stairs, passages and
gangways shall be provided with substantial handrails. Safe means of access are required at all working
places. To prevent fall, fencing or other devices are required.

Rule 66A of the Gujarat Factories Rules specifies access for fire fighting and requires
unobstructed layout .of plants and building and doors and windows on external walls ->for easy access
inside the building.
Means of access may be a ladder-portable or fixed, ramp, runway or stairway. They should
conform to the code or standards prescribed.
1.2.4 Safety Work Permit & Checklist :
A format of such permit is given in Table 22.2.
Table 22.2 : Safety work permit (swp), at construction site Date :
Date : SWP No. : ___________
SWP Requested by / Issued to : Project/ Location of SWP issue SWP Expiry

Section the work to Date & Time Date & Time
be done
Name of the Designation Company
person
Description / Nature of Equipment / tools to be Probable Hazards Tick 

the work used Tick 
 Cranes  Fall of persons from  Suspended load
height
 Chain pulley blocks  Falling objects /  Failure of sling/
overhead work tackles
 Slings & other lifting  Fall below ground level  Toxic
tackles dust/fumes
 Electrical equipment  Electrical shock  Fire
 Power hand tools  Moving machinery  Poor
illumination
 Others (write)  Ionising Radiation  Other causes
(Write)
 Eye injury (flying
object/arc)
Following safety measures/ Following safety measures / Remarks / special instruction if

precautions are necessary and have precautions to be taken / ensured any by issuing authority (pl.
been taken / ensured. during execution of the job. specify)
Tick  Tick  viz., display of warning signs
 Proper means of access  All workmen use safety to warn against overhead
(Ladders etc.) helmet. hazards etc.
 Proper scaffolding / work  Workmen use safety belt &
platform with hand rails. anchored properly.
 Static (Rope) line  Use of safety goggles and
safety shoes by the
workmen.
 Safety net  Safety belt  Provision of shoring /

machine
 The crane is in good working  Guards on moving machines
condition. are in place.
 The crane operator is  Static lines are provided and
competent & has licence. used by the workmen at
height.
 Electrical equipment provided  Cordoning off deep
with proper earthing. excavation/ hazardous area
with warning signs.
 Power supply to hand tools  Hand lamps (24V) to be used
thro’ ELCB. with safety guards.
 Hazardous area barricaded /  Power supply to lighting
protected. through ELCB.
 Condition /capacity of lifting  Specified work procedure
tackles ensured. adhered / Tool box talk
given.
 Specific work procedures is  Workers possess the required
necessary / available. skills.
 Area below hazardous  Others (Write)
overhead activity cordoned off.
Signature of the permittee: Signature of the site engineer/ Permit issuing authority :
Signature of the site engineer: Name & designation
A checklist for construction safety is given in Table 22.3.
Table 22.3 Construction Safety Checklist
Name and address of the Construction Company _________________ Working at _________________

Audited by ________________________ Audit date _____________
No. Checkpoints Comments

1 Helmets used by all
2 Safety belts used by all during work, if height is more than
2 meters.
3 Static lines are provided to facilitate hooking of safety
belts.
4 Safety nets are provided where scaffolds not feasible.
5 Scaffolds are in good condition, ladders are used.
6 Hand tools are of standard type and maintained properly.
7 Power tools are in good condition and supply through
ELCB.
8 Grinding machines are with guards.
9 Welding machine and cables are in good condition.
10 Gas cylinder of cutting sets are protected from spark.
11 Hose of cutting sets, pressure regulators and pressure
gauges are in good working condition – leak free.
12 Good insulation, earthing and ELCB are maintained in
electrical installations.
13 Cranes are in good working condition.
14 Lifting tackles are in good working condition.

15 Crane is operated by competent operator.
16 Standard signaling and rigging practices are followed.
17 Area where heavy erection is done is barricaded.
18 Area where load is lifted or suspended by crane is
barricaded.
19 Fire hazards are taken care of combustibles removed from
site of hot work.
20. Fire extinguishers are provided.
21. Floor openings are protected / covered / guarded.
22. Procedure for critical job is available and followed.
23. Persons employed on job possess required skills.
24. Vessel entry permits are taken for confined space entry.
25. Safety permits are taken to work at height.
Signature of Auditors _____________________
1.2.5 Good Housekeeping :
See Chapter-8 for details.
Good housekeeping programme should include
1. Speedy removal of scrap, waste, debris, loose and unused materials at regular intervals.
2. Proper storage of materials, tools and equipment. Removal of nails from lumber before stacking.
3. Cleaning of floors, passageways, stairs etc. to remove oil, water, dust etc. Sand, ash, sawdust and
proper absorbers can be used.
4. Containers should be provided for collection and separation of waste. Flammable/ hazardous
waste should be covered and safely disposed off.
5. After completion of any job, excessive materials, tools and equipment should be lifted and placed
in their proper place.
6. Piles of materials should be stable and properly supported.
7. Throwing of material should be avoided. If it is to be thrown, warning signals should be given.
8. Proper painting and colour-coding should be followed.
9. At least at the beginning and end of a shift, supervisors should take round to check above points.
2 STATUTORY PROVISIONS
See Part 7 of Chapter-28 for the Building and other Construction Workers (Regulation of
Employment and Conditions of Service) Act, 1996 and Central Rules, 1998 under this Act. These rules
came into force from 19-11-1998. Out of 252 rules, 200 are pertaining to safety & health of construction
workers and prescribe much detail. Henceforth it will be referred as 'BOC Workers Rules 1998' for
brevity's sake.
The above rules prescribe for safety committees (for workers 500 or more). Safety Officer (for
workers 500 or more), reporting of accidents, medical examination of building workers, occupational
health centre, construction medical officer, ambulance room, ambulance van, stretchers, occupational
health services, notice of poisoning or occupational diseases, first-aid boxes, emergency care services,
provisions for working hours, rest interval, spread over, weekly holidays, notices and registers, latrine
and urinal, canteen for workers>250 and payment of wages.

Its Chapter-VI, rules 34 to 54 prescribe for excessive noise, vibration, fire protection, on-site
emergency plan (for workers>500), fencing of motors etc., excessive weight, health and safety policy,
overhead protection, dust, gases and fumes, eye and head protection, electrical hazards, vehicular traffic,
structural stability, stacking of materials, disposal of debris, use of safety helmets and shoes etc.
The other provisions are regarding registration, responsibilities and duties, lifting appliances and
gear, runways and ramps, work on or adjacent to water, transport and earth moving equipment, concrete
work, demolition, excavation and tunnelling works, steep roof, ladders, catch platform, safety belts and
nets, structural frame and frame work, stacking and un-stacking, scaffold, cofferdams and caissons,
explosives, piling and powers of Director General and Inspectors.
See Part 2 of Chapter-? for provisions under the Factories Act and Rules. Some provisions
regarding construction of a factory, plant layout, lighting, ventilation, safety aspect and preparation of
plans stated therein are useful for general construction work also.
3 INDIAN STANDARDS
The Indian Standards on Construction are most useful and must be followed. Some of them are
mentioned below :
Safety in excavation 3764, scaffolds and ladders 3696 (Part I & 2), 4014 (Part I & 2), code of
practice for design and construction of pile foundations 2911 (Part I to 4), blasting and drilling 4081,
underground blasts 6922, demolition of buildings 4130, tunnelling work 4756, piling and deep
foundations 5121, structural steel work 7205, concrete framed structures 8989, cement manufacture
12770, construction machinery 7293, handling and storage of building materials 7969, additional
construction and alteration to existing buildings 13430, hazards prevention 13416 (Part I falling material
hazards. Part 2 fall prevention), working in compressed air 4138, floor and wall openings, railing and toe
boards 4912, wooden flush door shutters 2191 (Part I & 2), use of hot bituminous materials 5916, fibre
rope slings 9944, dress divers 10291, river valley projects 10366 (Parts I to 10), sewerage system 11972,
protective barriers in and around building 13415, reservoirs, guidelines for operation 7323, shallow
foundation 1904, masonry walls 1905, loading standards 875, underground air raid shelter 5499, bucket
elevators 7167, conveyor belting 6687, conveyor safety 7155, fire resistance test of structures 3809, fire
safety of buildings (general), details of construction 1642, fire safety of industrial buildings; cotton textile
mills 3079, fire safety of industrial buildings, storage and warehousing 3594, noise reduction in industrial
building 3483.
Glossary of terms relating to corrosion of metals 3531, design practice for corrosion prevention of
steel structures 9172, cathodic protection of steel structures 8062 (Part I to 4), fire precautions in welding
and cutting 3016, approval tests for welding procedures 7307.
See Chapters 7 (Table 7.1 & 7.2), 9, 10, 12, 15, 16, 17, 18, 20, 21, 23, 24, 25 and 26 for the
relevant Indian Standards pertaining to construction, building, working at heights and depths, material
handling, tools, fire safety, other hazards, PPE and first-aid.
See Parts 6 & 10 of Chapter-23 for other IS. '
OSHA Safety and Health Standards for the Construction Industry (29 CFR Part 1926) may be
referred for more interest.

4 CONSTRUCTION MACHINERY
Construction machinery can be classified into three categories as under
1 Lifting Appliances and Gear :

Pulleys, chain pulley blocks, winches, hoists, derricks, gin poles, cranes (fixed ad mobile), lifting
ropes, slings etc.
2 Transport, Earth-moving and Material Handling Equipment:
Power shovels (excavators), bulldozers, scrapers, pavers, road rollers, pile drivers, mobile asphalt
layers and finishers.
3 Plant machinery. Equipment and Handtools
Concrete mixers and vibrators, pneumatic compressors, pneumatic tools, cartridge operated tools,
electric tools, hand tools, conveyors, crusher plants, power generators, engines and silos.
' Some salient safety features of these machines/ equipment are explained below :
4.1 Lifting Appliances and Gear :
For figures and pictures see Chapter 15.
Pulleys : Select the pulleys as per requirement. Steel and nylon rope should not be used together.
Grooves should be uniform and smooth and the rope (wire or fibre) should run free. Sheaves, shafts,
hooks and pins (with locking) should be checked before use and lubrication shall be provided where
necessary. Sheaves should rotate freely on the shaft. The shaft should be free from any defect or crack.
Worn out shafts should not be used. Anchorage should be firm and strong. Anti-twister should be used to
prevent rubbing of the ropes with one another.
Chain Pulley Blocks : Refer Sec. 29 of the Factories Act. Select the lifting capacity depending on
the maximum load to be lifted. Verify its test certificate. Check for slipping of load, jamming of links and
free operation. The chain should not come out of pulleys. It is better to lubricate before every use. It
should be tested periodically by a competent person (see Rule 60, and Form No. 10, GFR). The
anchorage should be strong and rigid. It should be checked for cracks, wear and tear, elongation etc.
Opened out hooks and tampered block/puller should not be used. No cannibalising should be done on
chain pulley blocks.
See Chapter-Vm, Rule 55, 56, 74, Schedule-1 and Forms V to X of the BOC Workers Central
Rules, 1998, for statutory details. See subsequent Part 6.5 and Part 7 of Chapter-28 for further details.
Winches : Safe working load with gear arrangement should be marked on the winch stand. A
winch should be placed on a firm base, properly anchored and should not be overloaded. Brake, ratchet
arrangement, gear and pinion, meshing, wire rope and its clamping, rope drum and tie rods should be
checked before every use. Tie rod should be adjusted to prevent clutch arrangement to slip. Ratchet
arrangement should be kept in position while hoisting a load.
See Rule 59 of the BOC Workers Central Rules, 1998, for statutory details.
Hoists : Refer Sec. 28 of the Factories Act. Design should be as per standard code. Outdoor hoist
towers should be erected on firm foundation, securely braced, guyed and anchored. Ladder way should
extend from bottom to top. Hoist shaft (way) should be enclosed with rigid panels or fencing at all
landing platforms, access or where any person is liable to be struck by any moving part. The shaft
enclosure, except at approaches, should be of 2 mt (minimum I mt) height above the floor or platform to

prevent any person falling down the hoist way. Hoisting engine or motor should be capable of controlling
the heaviest load. When the cage or platform reaches its highest point, it should be stopped automatically
(no overrun).
Hoist platform or cage should be capable to carry the maximum load. It should have a safety gear
to hold it if the rope breaks. At the ground floor coil springs should be provided to arrest any accidental
fall. Cage or platform should have toe-boards or enclosures to prevent fall of material inside.
Counterweights should run in guides. Interlock door should be provided where any worker has to enter
the cage.
Notices of carrying capacity (weight/ persons) should be displayed.
Factory hoists/lifts should be thoroughly examined by a competent person at least once in 6

months with report in Form No. 9 (Rule 58, GFR). See Rule 65 & 78, Form VI of the BOC Workers
Rules, 1998 for more details.
Derricks : They are of two types : Stiff-leg derricks and Guy derricks.
Stiff-leg derricks should be erected on a firm base to withstand the weight of the crane structure
and the maximum load. Masts should be prevented from lifting out of their seating. The jib length should
not be altered without consulting the manufacturer. Counterweights should be so arranged that they do
not subject the backstays, sleepers or pivots to excessive strain. Electrically operated derricks should be
properly earthed.
In case of wheels-mounted derricks the correct wheel distance should be maintained by a rigid
member and struts should be provided to give support if a wheel brake fails or the derrick is derailed.
The mast of guy derricks should be supported by six equi-distance top guys and the guy spread
angle from the mast should be less than 45° from the horizontal. The restraint of the guy ropes should be
ensured by fitting stirrups or anchor plates in concrete foundations. Guy ropes should have a device to
regulate tension. Pins and bearings should be lubricated frequently. When not in use, the derrick boom
should be anchored to prevent it from swinging..
The derrick should be tested by a competent person and should not be overloaded. The mast,
guyropes, wire ropes, swivel hook, rope clamps etc. should be checked before erecting the derrick.
Welded or bolted joints/parts should be checked for crack, defect and tightness.
See also Rules 67 & 68 of the BOC Workers Rules, 1998.
Gin Poles : They should be straight, made of sound metal or straight timber without knots, of
sufficient strength and adequately guyed and anchored. They should be adequately fastened at their feet
to prevent displacement. Before their re-erection, the pole, ropes, guys, blocks etc. should be inspected
and tested under load.
Cranes (Fixed & Mobile) : Refer Sec. 29 of the Factories Act and Rule 60, GFR.
The crane capacity should be ascertained and brakes checked before lifting a load. Mobile crane
should be parked on hard soil and not near any pit or excavation.

Safe working load of any crane depends on (a) condition of the ground (b) boom length (c)
inclination of boom to the vertical (d) radius of rotation while lifting the load (e) out rigger blocked or
free and (f) ' operator's skill.
The safe working load should be displayed in the crane. It should be derated (lowered) due to
defects in welding, bend in angle, bracing and conditions of clutch, brake etc.
Devices should be provided to prevent load being moved to a point where the corresponding safe
working load of the crane would be exceeded.
Standard signalling code, understood by the operator and trained signalman, should be followed.
See Fig. 15.1 of Chapter 15. The crane operator shall respond to signals only from the appointed
signaller, but shall obey a stop signal from anybody.
Tag lines should be used while hoisting heavy and bulky load. The crane and its parts (brakes,
boom, hook, wire ropes, pulleys etc.) should be checked regularly and maintained in good condition.
The load should not touch the boom and the boom should not touch any live electric line or
structure. Quality of packing should be checked before lifting. Nobody should stand below the boom or
load. The operator should be able to see the hook and the load, should keep his windshield clean for clear
vision and deck clean of any oil, mud or dust.
When the hooks are lowered to the lowest point, at least two dead coils should remain on the rope
drum. Makeshift methods to increase the capacity of a crane are unsafe.
During storm, the hook block should be anchored firmly and swing lock be released. At the end of
work, the load should be removed from the hook and the hook should be raised to the maximum height.
The mobile crane should have horn, head lights, side lamps, rear and stop lights and flashing
direction indicators. Jib crane should keep the job lowered while travelling without load.
While travelling up a slope, the load radius should be decreased and while travelling down, that
radius should be increased. Constant watch on the radius is necessary while travelling on uneven
surfaces.
Air pressure in the tyres should be equal, otherwise tilting is possible. .
While operating tower cranes, wind loads should be considered and trained operators should be
employed to sit in cabs at height. Wind speed indicator should be provided in the driver's cab.
Where two or more cranes work side by side, direct communication system should be provided in
the cab to alert the other driver about danger zone. Minimum distance between two approaching cranes
should be maintained by limit switches.
See Rule 57, 58, 63, 64, 74, 80 & 81 of the BOC Workers Rules, 1998 for other details.
Lifting Ropes, Slings etc. : Safe working capacity of the lifting ropes must be known beforehand.
Ropes, slings, rings, shackles, tackles, chains, hooks, swivels etc. should be installed, maintained and
inspected as per Sec. 29 of the Factories Act and Rule 60, GFR. Repaired ropes should not be used in
hoists.

Where multiple independent ropes are used to lift a load, each rope should be capable of carrying
tile load independently.
See also Rule 71 of the BOC Workers Rules, 1998.
4.2 Transport, Earth-moving and Material Handling Equipment:
All vehicles and earth-moving and material handling

equipment should I have following general provisions.
They should be of good design, sound material and construction,

adequate strength and maintained in good working order. Principles of
safety and ergonomics should be considered in design and operation.
Operators/drivers should be well trained, medically examined,

physically fit and above 18 years of age. They should be competent,
reliable and follow the signalling code. Help of authorised signaller must be taken while driving
backwards or the view is restricted. They should be protected against weather, dust, load being lifted and
possible accidents.
All vehicles should be equipped with proper lights, horns, silencers, power and hand brakes and
reversing alarm. Their motors, engines, brakes, gears, chassis, blades, tracks, wire ropes, sheaves,
transmission parts and pneumatic, hydraulic systems should be checked daily before use.
The vehicle or machine should not be left unattended with the engine running. Deck plates and
steps should be kept free from oil, grease, mud etc. The cab should be kept at least I m away from a face
being excavated. Bucket excavators should not be used at the top or bottom of earth walls with a slope
exceeding 60°. Gross laden weight, tare weight, maximum axle weight and ground pressure in case of
caterpillar should be indicated.
When not in use, the boom should be in the direction of travel and scoop, shovel or bucket be
raised and without load. Safe parking place should be provided where more vehicles have to work.
Nobody should be allowed to rest or sleep under the vehicle.
Power Shovels (Excavators) : They should be equipped with emergency stop device and two
independent locking devices for brake pedals. The bucket teeth should not come nearer the boom than 40
cm. Safe working load of the lifting gear should be displayed in the cabin and its indicator should be
fitted. The boom should be prevented from swinging during transport. The boom should not be pulled
tight against the emergency stop while supporting a load. The wire ropes should be of specified diameter
and construction. The safe operating radius shall not be exceeded.
The shovels should be so operated as not to loose their stability. The driver should see that no
person is under or near the raised bucket or grab. When not in use, the bucket shall be kept resting on the
stable ground and not hanging. Truck to be loaded should be stationed at 60 cm. or more from the
excavator even when it turns. Earthing and fire extinguisher should be provided where necessary.
Bulldozers : While moving uphill, the blade should be kept low. The blade should not be used as
brake except in emergency. The blade suspension arrangement, wire rope or hydraulic system should be
inspected weekly.

At the close of work, the bulldozer should be left on level ground and before leaving it, the
operator should apply the brakes, lower the blade and ripper and put the shift lever in neutral.
Scrappers : The tractor and scrappers should be connected by a safety' line when in operation.
Scrappers moving downhill should be left in gear. Scrapper bowls should be propped when blades are
being replaced.
Pavers : Guards should be provided to prevent workers from walking under the skip.
Road Rollers : The land should be checked for bearing capacity and general safety before using a
road roller. While moving downhill the engine should be in gear. When it is not in use, the brakes should
be applied, the wheels should be blocked, the contact should be switched off and the engine should be in
bottom gear if the roller is facing uphill and in reverse gear if it is facing downhill.
Pile-drivers : All pile-driving equipment should be of good design and construction and properly
maintained. Ergonomic principles should be considered. Pile-driving should becarried out under the
supervision of a competent person. Underground services should be located and rendered safe before
starting piling. Pile drivers should be firmly supported on sound foundation. If necessary, they ' should be
guyed also. If two pile-drivers have to work nearby, they should be separated by a distance at least equal
to the longest leg.
If electrical conductors are in proximity, they should be made dead. When leads have to be
inclined, they should be counterbalanced and tilting device should be secured against slipping. The hoses
of steam and air hammers should be securely lashed to the hammer so as to prevent them from whipping
if a connection breaks. Overturning of a pile-driver has to be prevented. Out coming of the rope from the
top pulley or wheel and missing of hammer from the pipe should also be prevented.
Pile lines and pulley blocks should be inspected before the beginning of each shift. Only trained
operators should be employed. Use of suitable signals, ear protectors and safety helmet is necessary. Piles
should be prepared at a distance at least equal to twice the length of the longest pile from the pile-driver.
When not in use, the hammer should be blocked at the bottom of the leads.
When pile-drivers are working over water, a suitable boat should be kept readily available at all
times. Whistle, siren, signals, fire fighting equipment and sufficient sheaves should be provided, the
weight of machinery should be evenly distributed and watertight compartments should be provided with
siphons to remove water seepage.
Mobile Asphalt Layers and Finishers : The mixer elevator should be within a metal enclosure
with a window for observation, lubrication and maintenance. Bitumen scoops should have covers. The
sprayer should have fire resistant shield with an observation window. Non-foaming products are
preferable. Reflective jackets should be provided to workers working on public roads.
The fire extinguishers are necessary near spreader and others in readiness. No naked flame should
be used to see the level of asphalt in the tank. Thinners should not be heated on open flame. Inspection
doors should not be opened if there is any pressure in the boiler.
If a burner flame is extinguished, the fuel supply should be cut off and the heating tube should be
thoroughly blown out by the fan to prevent backfire.
See Chapter-X, Rules 88 to 95 of BOC Workers Rules, 1998, for statutory details of the above
equipment.

4.3 Plant Machinery, Equipment and Hand Tools :
For figures and pictures see Chapter-17.
All such machinery, equipment and tools should be of good, ergonomic and safe design,
maintained in good working order and operated .by trained operators with necessary personal protective
equipment. Safety instructions from manufacturer and safe operating procedure should be followed.
Power driven equipment should be properly earthed, stop switch provided in close proximity,
adequately guarded, speed regulated and when not in use, switched off (de-energised) and isolated before
any major adjustment.
Concrete Mixtures : All gears, chains, rollers and open revolving blades should be guarded or
fenced. Hopper should be protected by side railing to prevent workers from passing under the skip.
Hopper hoisting wire rope, brake, skip hoist clutch and blocking (fixing when raised) device should be
checked and adjusted regularly. Double earthing and insulation of electrical part is necessary. Before
allowing a person to enter the drum for cleaning or repair, electrical connections (fuses) should be
removed.
Concrete bucket towers and masts with pouring gutters or conveyor belts should be erected by
competent persons and inspected daily. The winch operator should be able to see the filling, emptying
and lowering of bucket, otherwise a banks-man should direct the operator. Guides for bucket should be
correctly aligned to prevent the bucket from jamming in the tower.
Structure or scaffold carrying a pipe for pumped concrete should be strong enough (factor of
safety 4 or more) to support a filled pipe and all workers on it. Such concrete carrying pipes should be
securely anchored at the ends and at curves, provided at top with air release valves and securely attached
to the pump nozzle.
Concrete Vibrators : Vibrating unit should be completely enclosed and belt be guarded.
Electrical vibrator should be protected by overload relays and earthed. Cable length should be sufficient.
Needle load should be firmly locked. Needle inner core should be lubricated.
See Chapter-XI, Rules 96 to 107 of the BOC Workers Rules, 1998 for Concrete Work.
Pneumatic Compressors: Testing by a competent person is necessary. Air receivers should be

equipped with a .safety valve, pressure gauge, drain cock and openings for inspection and cleaning. It is
safer to provide a PRV, a stop valve and an oil separator between the air receiver and the compressor.
Compressors should be equipped with an automatic device to control the safe discharge pressure,,
a quick release valve and suitable arrangements to prevent or remove contamination in a confined space.
Where explosive gas mixture may be formed in compressor, it should be protected against sparking.
Water flow should be ensured in water-cooling jackets. Inter and after coolers should be able to
withstand the maximum pressure in the air discharge piping. Such piping should be provided with a
fusible plug and insulation to protect workers against burns and fire risks.
Where stop valves are installed in air-discharge piping, they should be easily accessible for
inspection and cleaning and one or more safety valves should be installed between the compressor and
the stop valve.

Pneumatic Tools : Operating triggers on portable pneumatic tools should be so placed as to
minimise the risk of accidental starting of the machine and so arranged as to close the air inlet valve
automatically when the pressure of the operator's hand is removed. Air hoses and their connections
should be equipped with safety clips or retainers to prevent dies and tools from being accidentally
expelled from the barrel. Before any adjustment or repair, power should be disconnected and pressure in
hose lines be released.
Cartridge-operated Tools : Preferably low velocity tool should be used. Such tools should have
a cover (guard) which cannot be opened without rendering the tool inoperative, devices to prevent from
accidental firing, to prevent firing if the muzzle is not pressed and to prevent firing if it is not
perpendicular to the working surface.
The recoil should not be capable of injuring the user. The tool should be inspected for all safety
devices and to see that the barrel is unobstructed.
Cartridge-operated tools should not be stored or operated in explosive atmosphere. When not in
use, it should be kept in its special container for the purpose of safety.
Electric Tools : Portable electrical tools' should be operated at low voltage and with ELCB to
avoid risk of shock. The tools should be properly earthed with metallic cases. All insulated or double
insulated tools need not be earthed. Periodic inspection and maintenance should be carried out by a
competent electrician. Proper fuse and insulated handle are necessary.
Hand Tools ; They should be tempered, dressed or repaired by a competent person. Cutting edges
should be kept sharp. Heads of hammers and other shock tools should be dressed or ground as soon as
they begin to mushroom or crack. When not in use or while carrying or transporting, they should be kept
in suitable containers.
Insulated or non-conducting tools should be used near live electrical installations. Non-sparking
tools should be used near flammable vapours.
See Part 3 of Chapter-17 for more details.
Conveyors : Conveyors should be smooth running. Nip between tight belt and pulley/roller and
other transmission parts should be guarded. If they are not entirely enclosed, at cross over places, bridge
with hand-railing should be provided. Emergency stop-devices (e.g. cord or cable) should be easily
accessible. Stop buttons should be provided at drive and take-up ends. Where two or more conveyors
operate together, control devices should be so arranged that no conveyor can feed on to a stopped
conveyor. When a conveyor is discharging into a bunker or hopper, the feeding conveyor should be
provided with an overload switch.
Screw conveyors should always be kept covered. The cover should not be opened without
stopping the conveyor.
See Part 3.6 of Chapter-15 for more details.
Crusher Plants : They should be located away from construction area to keep away dust, sand,
gravel, noise and vibrations. Extra isolation switch should be provided to prevent accidental starting
during repair or maintenance. Electrical motors, switches and instrumentation should be dust and
moisture proof. Access roads to the crusher hopper and screens should be cleaned by water spraying.

Power cables should be laid underground or at safe elevation. All equipment, plant and machinery should
be cleared daily of dust and sand.
Power Generators: They should be housed in a concrete room or insulated area to minimise
noise effects. Silencers and exhaust pipes should be provided. Extra isolation switch should be provided
to avoid accidental starting during maintenance.
Engines : Maximum safe speed should not be exceeded. Remote control device should be
provided to stop or limit the speed. For internal combustion engines, exhaust ventilation should be
provided and while fuelling, spark should be avoided and fire extinguisher should be kept ready.
Secondary fuel tank should be provided outside the engine room.
Silos : Silos should be erected on sound foundation and capable of withstanding stresses without
any deformation of walls, floors and other load-bearing parts.
Safe means of access (stairs, fixed ladders or hoists), quantity/level indicator, notices, blockage
remover and fire extinguishers should be provided.
In silos where explosive mixtures are possible, all electrical equipment and hand lamps should be
flameproof, non-sparking tools should be used and explosion vents should be provided in the walls at
safer points.
Before allowing workers in a silo, work permit should be made, charge (filling) opening should be
closed and safety belt with lifeline in the hands of another person outside, should be provided if they have
to work on loose material.
5 UNDERGROUND WORKS
Underground work includes excavations in surface soil or rock, drilling, blasting, trenching,
shoring, strutting, tunneling, piling, shaft finking, haulage and underground pipelines. It requires due
considerations of underground lighting, ventilation electricity, dust control, inrush of water, oil or gas and
continuous safety of people at work. Some provision are explained below:
See Chapter-XIII, Rules 119 to 168 of the BOC Workers Rules, 1998, for excavation and
tunneling works including warning signs and notices illumination, stability of structure, pilling, shoring
and bracing, safe access, trenches, tunnelling operation shafts, pneumatic tools, inflammable oils,
coupling an hoses, storing of oil and fuel underground, use of gases underground, water for fire fighting,
flooding, steel curtains, exposure limits of chemicals, ventilation, a locks, man-locks, medical lock,
emergency generated etc.
Similarly see Chapter-XXIU, Rules 214 to 222 ( the same rules for piling.
5.1 Excavation:

Foundation or underground support is required for most of the constructions and method of
reaching earth or rock stratum suitable for foundation is excavation. It may be with or without dewatering
the site and out of many methods a suitable method of excavation should be selected.
General precautions for any excavation or underground work are : survey of hazards of fall of
persons, soil, material etc., inrush of water, oil, gas etc., adequate lighting and ventilation to supply fresh
air inside, controlling gas, vapour, dust etc. within safe limits, fire precaution, safe means of access,
stability of the ground, position of public utility services such as electric or telephone cables, water, gas
or sewers line etc., effect on adjoining building, structure, roadways, bridges etc. A competent person
should make this survey and give permission to work.
If necessary, isolation of underground utility services should be effected by due permission or

otherwise be protected. Chemical waste and contamination should be safely removed.
No load, vehicle or material should be moved or stacked near the edge of excavation unless
shoring or piling is done to prevent the sides from collapsing. All support work such as props, wedges
etc. should be regularly checked for deflection or distortion. All sides should be fenced by barrier at least
up to 1m and a danger notice and red signal and light be provided.
Sides of all excavation must be sloped to a safe angle not steeper than the angle of repose of a
particular soil. See Table 21 of Chapter 32 for such angle of repose.
Cutting shall be done from top to bottom. No undercutting of side shall be allowed. In narrow
trenches a ladder should be extended from bottom to top and I m above the ground surface. Erosion of
soil over excavated pits, trenches etc. should be prevented from running water by dewatering pumps etc.
Road barrier at a distance should be provided if road is to be blocked. Helmets and gum-boots should be
given to all workers working inside.
In large scale excavations for dams, huge buildings, highways, railways etc., accidents occur
mostly due to the vehicles, dumpers, trucks etc. Therefore such vehicles must be checked for warning
sirens, horns, lights, signals, reverse alarm etc. Rules of driving should be enforced. Sufficient lighting
should be provided for night work.
5.2 Drilling, Loading and Blasting:

Drilling and loading are required before blasting.
Before starting drilling, any presence of unfired explosives should be carefully checked. No
drilling should be allowed in the butts of old holes. Before drilling, loose or disintegrated rock should be
removed by hand tools or pneumatic jack hammers to protect drillers against falls of material. Where this
is not possible, a protective canopy or overhead screen should be provided.
Holes are drilled by pneumatic hand-hold drills to a specific pattern. Compressed air hoses should
have self locking couplings. Drillers should wear helmet, hand gloves and gumboots.
After checking the drilling pattern and depth, the drilling crew is withdrawn from the site with all
drilling equipment and accessories. The blasting foreman will check all the holes to be loaded by
explosives and detonators for blasting. Transportation, storage, handling and use of explosives are
governed by the Explosives Act and Rules. See Part 3.3 & 3.4 of Chapter-28. No smoking or open flame
is allowed in explosive loading area. All the workers from this area are withdrawn to a safe place. Only
suitable battery lamps should be used during loading shot holes.
No holes should be loaded except those which are to be fired in the next round of blasting. Holes
loaded during one shift should be fired in the same shift. Diameter of the hole should be at least 3 mm
more than the dia of the cartridge. To avoid misfires, the detonator should be completely inserted length-
wise in the cartridge and fastened in such a manner that it cannot be pulled out accidentally. The
cartridges are not forced into the holes. Cap crimpers of proper design should be used for crimping the
blasting caps into fuse. A knife or teeth shall not be used for this purpose. Intensity of charge to be loaded
must be well calculated and safe enough to prevent damage to nearby structures due to shock and
vibration resulting form explosion.
Tamping of cartridge in the hole is done by a wooden (or non-sparking metallic) stick gently. If
dynamite is to be removed from cartridge, loose dynamite should not be tamped. Primer -shall never be
tamped. During tamping care should be exercised to avoid injury to fuse or cap wires. The holes are filled
with clay and sand sticks at the top. Detonators' wires should not be damaged or pulled out.
Then the continuity of the entire circuit is checked by a blasting circuit tester and the resistance of
the circuit is also measured. No other electric circuit should be allowed in that area or it should be de-
energised. Radio, TV and Radar transmitters can detonate electric cap. Hence minimum safe distance
should be maintained. The lead wires are connected to the exploder whose firing switches are kept 'open',
locked and keys with the blasting foreman. The surplus explosives/detonators are returned to the
magazines.
Then follows the warning procedure. 'Warning' and 'All clear' signals should be established and
made known to all concern. Trained persons are posted at all approaches with red flags to stop all traffic
and by passers.
The blasting foreman, then, sounds a warning siren to drive away all persons from the danger area
and not to allow anybody to enter in the blasting area. After being satisfied with the readiness of blasting,
the blasting foreman will fire the shots by closing the switch of the exploder. After dispersion of gases
and dusts, the foreman will return to the area and check for any misfire.
Misfire can be minimised by using good quality explosives, testing each electric cap with a
blasting galvanometer before loading or by testing the complete circuit before firing. The safest way to

deal with misfire is to re shoot it by new primer. If there is no misfire, then he gives 'All Clear' signal and
allows the removal of blasted materials. Loose rock should be scaled down.
Haulage i.e. pulling and shifting of material after blasting is carried out manually or mechanically.
Vehicles (train or trucks) should have head-lights, tail-lights and loud horns. Hauling by winch should be
done under the supervision of a competent person. Workers should not be transported along with the
material.
Blasting record should be maintained. Date and time of blast, number of holes, type of explosives
and detonator used, amount of charge per hole, firing pattern and sequence should be recorded.
5.3 Shoring and Underpinning:
Shoring and underpinning are required to stop settlement of a weak foundation, to strengthen the
foundation to carry added loads, to provide support because of adjacent operations and to prevent
deterioration of the foundation materials.
Shoring refers to removal of temporary supports after completion of job and underpinning refers
to providing permanent supports which remain in place even after completion of job.
Shoring requires skilled workers and cordoning off the area due to hazardous nature of the job. It
is to be carried out under constant supervision and control of qualified and experienced engineer. The
jack, needles and temporary supports should be of adequate capacity and strength to raise the structure.
Types of shores available are raking, flying, needle beam and post. The shores and needles to be
underpinned must be designed to withstand the anticipated load.
Underpinning is useful to stop settlement of the structure, or to give more support by new
foundations to withstand added load of the structure. This work is to be done rapidly, in a limited space
and with great care, to the existing structure. Adequate lateral bracing helps obviate the need of
underpinning interior walls or columns.
If damage results during underpinning and repairs required, it is best to wait till all settlement and
lateral movement are ceased.
Generally two methods are available for underpinning - the pit method and the steel cylinder or
caisson method. The pit method is used where new foundation is not to be very deep. In the other
method, the steel cylinders of caissons are placed under the existing footings and sunk to the rock. Skilled
workers are required due to restricted availability of working space and headroom. The shoring of the
column is removed at the end.
5.4 Tunnelling and Shaft Sinking:
Tunnels are required for road-ways and railways through mountain, hydro-power station
underground, irrigation of water, drainage, mining of minerals, storage of hazardous Wastes and defence
installations (underground shelter) etc.
Tunnelling may be in soft ground (clay, sand, gravel or soft earth) or in rock. Soft ground
tunnelling is carried out by fore poling, needle-beam and timber, liner plates, shield and liner plates and
plenum process or compressed air-lock. Rock tunnelling is carried out by drilling, blasting, mucking or

by machines which may be full face boring machine or the header with rotary milling head on a
telescopic boom.
Safety measures include well maintained equipment and tools, their testing by competent persons,
speedy removal of debris, refuse and trash, safe and adequate walkway, proper drainage and water
pumping if required, good lighting, use of helmet, gumboots and goggles by the workers, jumbo platform
with guard rails and toe-guards to work near the entire face of the tunnel to be drilled, pneumatic drills
with pusher legs, wet drilling for dust control, pneumatic coupling with self locking couplings, separate
transport vehicles for explosives and detonators and their separate magazines, safe handling of explosives
and detonators, avoidance of spark, no smoking in explosive area and all precautions mentioned in
foregoing Part 5.2 for drilling, loading, blasting and haulage.
After blasting, rock falls can cause major accidents. Therefore inspection of walls and roofs,
scaling of loose rock, bolting and supporting of weak spots, checking of weak seams and planes by a
hand hammer and supporting of roof and sides are essential.
Mechanical loading of muck and haulage are required for speedy construction in tunnel. Muck
(dirty thing) cars should be loaded evenly and not piled above the sides. Vehicles in tunnel should not run
overloading and overspeeding. Rail-tracks should be safe and sound. Smokeless locomotives should be
used. Dump cars should be with locking device to prevent accidental tipping.
When tunnelling is done through a shaft (vertical rod or stem), the tunnel musk is hoisted through
die shaft and brought to surface for disposal. Hoisting machines should have automatic brakes to stop and
hold the conveyance (cage or car) if the hoisting power fails. It should have a depth indicator. Rules for
hoist/lift should be followed as mentioned in foregoing Part 4.1.
Mechanical ventilation is necessary in all tunnelling work to supply fresh air to the working crew
and removal of dust, fumes and gases including methane, CO, etc. Rock dust containing silica and quartz
may cause silicosis. Ventilation ducts should be airtight and should have reversible duct blowers to
operate in both directions.
The tunnels are lined with plain or reinforced concrete or steel forms to support the surfaces and
to prevent any rock fall. Scaffolding carrying pipeline of pumped concrete should be strong enough. The
workers should wear face shield or safety goggles.
Safety precautions for shaft sinking are mostly same as stated above. The shaft which is not sunk
through solid rock should be cased, lined or otherwise made safe. Workers should be provided with
cradles from which they can work safely. The shaft top should be protected by fencing or guard-rails, toe-
boards and gates. Means of escape and ladder from bottom to top should be provided in addition to any
mechanical means of ingress and egress. Winches at shaft tops should provide easy replacement of
bucket. All landings in shaft should have gates that close the opening to a height of at least 2 mt.
All shafts of over 30 mt in depth should have an adequate head frame strong enough to withstand
the maximum load. It should be open steel work, fire resistant and protected against lightening.
Shafts should have a signalling system that warns the hoisting man when a conveyance passes
beyond the safe limit of travel. The signal code should be posted in the hoisting machine room and at
each landing.
No combustible material or structure should be allowed within a shaft, tunnel mouth, engine
house or fan house. Lubricating oils, grease and rope dressings should be kept in closed metal containers

and away from shafts. Electrical installations in shafts and tunnels should comply with rules and
regulations. Lightening arresters should be provided on the surface. Emergency lighting to function for a
long time (to escape safely) should also be provided.
6 ABOVE GROUND WORKS
Most of the construction works in the form of concrete, steel, wood or mixed structure are found
just on the ground. Basic requirements to work at height as the work proceeds, are scaffolding, ladders,
staircases, centring, formwork, wall and floor openings, structural steel work and machinery and
equipment for the movement of material and men.
6.1 Scaffolding, Ladders and Staircases:
See Chapter XV, Rules 172 to 174 for ladders and Chapter XIX, Rules 188 to 205 for scaffold, of
the BOC Workers Rules, 1998. See Part 7 of Chapter-28 for their details.
6.2 Structural Frames, Formwork and Concrete Work
All such works require trained workers and the supervision of qualified and experienced engineer.
Temporary work (formwork, slip form, shuttering, false work, shoring etc.) should be safe enough to

withstand loads on it and working platforms, ladders, bracing etc. can be attached to it. Safety of workers
from temporary, unstable- or weak structure has to be foreseen.
See Chapter XVII, Rules 181 to 185 for structural frame and framework and Chapter XI, Rules 96
to 107 for concrete work of the BOC Workers Rules, 1998. See ' Part 7 of Chapter-28 for their details.
6.2.1 Erection and Dismantling of Steel and Prefabricated Structures
Safety of workers should be ensured by providing sound scaffolds, platforms, ladders, gangways,
boatswain's chairs, safety belts, fall arrester nets and lifting appliances including power driven mobile
working platforms. All such platforms must have safety railing (at least 1 mt high), hand rails and toe-
boards. Free end of the safety belt must be tied with a fixed and strong support. Helmets, goggles,
gloves, aprons and other equipment should be worn by the workers.
Floors, stairs and platforms should be dry, clean and non-slippery. This
can save many injuries.
Hooks for lifting and transporting prefabricated parts or material

should be of self-closing type and withstand load and stresses. Precast
concrete parts should be allowed to set and harden for its full strength.
Stores and racks of steel and prefabricated parts should be on firm
ground and so arranged as no part should fall or overturn. Lifting
appliance should be suitable and tested at 20% more load. Tongs,
clamps etc. should be capable of securing grip and marked with
maximum permissible load. Lifted structure and wall units should be so placed that they do not fall by
wind, jerk or other factors.
Adequate instructions should be given to the workers for safe erection. If due to high wind, rain,
snow or reduced visibility, it becomes unsafe to work, the work should be interrupted. Parts to be erected
at a greater height should be assembled on the ground. While lifting prefabricated parts, area underneath
it should be barricaded. Steel trusses being erected, should be firmly shored, braced or guyed until they
are permanently secured in position and no workers should be allowed to work under them at that time. A
boom or any moving part of a crane (including the load lifted) should not touch such trusses. In absence
of such precautions, six workers died in one accident 'when trusses fell down on workers working
underneath. No load-bearing structural member should be weakened by cutting, drilling etc. Open-web
steel joints should be directly placed in position and secured against dislodgement.
6.2.2 Cast-in-situ Concrete Structures :
The planning of construction of cast-in-situ, large span and multi-storey concrete structures
should provide information on specifications of materials to be used, methods of safe placing and
handling, reinforcement design and load-bearing calculations. During construction, a daily progress
report should be maintained, stagewise erection procedure should be prescribed, defects watched
continuously and loads should not be dumped or placed on setting concrete.
6.2.3 Wall and Floor Openings :
Walls should be on sound footing, perfectly vertical, properly joined and of sufficient thickness
for strength and load-bearing. Brick joints should be properly aligned, cemented and pointed if required.
Plastering and colour coating give extra protection. Support of the wall under construction should not be
taken but a scaffold should be used. Doors, windows, ventilators and other openings in walls should be,

provided as per requirement and drawing. As per Rule ISA, GFR, they should be at least 15% of the floor
area. Bottom of a window should begin within 1 mt from the floor.
Floor construction uses a variety of material depending on choice. Earth filling with cement or
cement concrete is necessary for strength. Wooden planks, steel grate (grill) or plates, tiles, stones,
marble, cement concrete, asphalt etc. are some of the flooring materials.
Floor openings are required for erection of hoist or lift way, tank, vessel or reactor, piping etc. Till
these floor-gaps are not occupied by their proper fittings, they pose danger of falling from height.
Therefore Section 33 of the Factories Act requires that all such floor openings should be securely covered
or fenced. If any gate is provided at any landing platform, it should be kept locked (not simply closed and
openable) when any person has to work near it. In absence of such unlocked gate, a worker- fell from a
30 mt height and died on the spot.
Temporary floors should be securely covered with close planking or other covering until it is
replaced by a permanent floor. Parts of protection should only be removed to the extent required for the
progress of the work. In skeleton steel structures, permanent floor filling should be installed as the
erection progresses.
6.2.4 Formwork and Slip forms:
Tubular steel frames used as staging to support concrete form-work should have a safety factor of
at least 2 and be used as per manufacturer's recommendation. Struts and/or diagonal braces must be in
proper position and secured for frames to develop full load carrying capacity. As erection progresses, all
connecting devices should be in place and fastened for full stability of joints and nuts. As height increases
above two tires, suitable planking should be used as a working platform. During concrete pouring
operation, staging system should be constantly watched and corrected if necessary.
Concise procedures to cover all stages of work should be prepared and supervised by a competent
person. Foundations should be checked for ground conditions. Drawing or sketch for shuttering should be
explained to workers. Shoring should be provided for support and should not be removed until
authorisation and the concrete has acquired sufficient strength. Shoring should be braced or tied together
to prevent deformation or displacement. Mechanical, hydraulic, pneumatic or vacuum lifting devices
should have automatic holding device in case of power failure.
Workers placing reinforcement rods and unloading concreted above the slipform platform should
wear safety belts and lanyards to protect from falling. Slipform floor where reinforcement rods are being
lifted should have temporary barricades. While lapping/ joining vertical reinforcement rods, the
projections should be tied to prevent their falling off inadvertently.
6.3 Structural Steel Work and Erection:
A fabrication yard should be well away from a rail-track, road, overhead transmission, lines,
boiler house and source of ignition. While unloading structural steel wagons or trucks by crane, wheels
should be made stationary by fixing wedges and nobody should stand under a hanging load. While
putting heavy structure, supports (props) should be given to prevent toppling. At both ends of a gantry
crane, stoppers should be provided. Leather gloves, goggles etc. should be used as per requirement.
Portable tools should have guards, proper fuse, earthing and ELCB in power connection. See Part 6.2.3 of
Chapter11.

In erection work load should be ascertained for centre of gravity and its transfer at the slinging
point. Lifting machines, ropes, slings, tackles etc. should be checked for its good working order and
safety. Eye bolts should be provided at correct slinging points while lifting heavy machinery such as
motors, turbines, generators etc. No sling should be overloaded. Signalling code should be known to all.
Proper tag line should be used for guiding while lifting loads.
Stack of structural members should be such that light members should be at the top and in
sequence of erection and not in a position to roll down or slide while handling. Clear passages, should be
allowed. Hands should not be jammed against any object. Bolts, nuts, tools etc. should be kept in boxes
and not loose on the structure. Vertical column should be tied by 4 guy ropes and only after bracing or
fixing, the ropes may be removed one by one. Precautions in placing trusses are explained in foregoing
Part 6.2.1. CGI sheet should be lifted manually by proper system. It should not fall. They should be kept
tied on top and bolted or stitched ultimately.
6.4 Welding and Cutting Operations :
See Part 7.1 of Chapter 20, and Schedule 24, Rule 102 of the Gujarat Factories Rules.
6.5 Lifting Machinery and Equipment:
See Part 3.5 of Chapter 15, and also foregoing Part 4.1.
See Chapter VII, Rules 55 to 81 including Schedule 1 and Forms V to X, of the BOC Workers
Rules, 1998, for statutory provisions of lifting appliances and gear. This chapter prescribes details of
construction and maintenance of lifting appliances, their examination, automatic safe load indicators,
winches, buckets, safe working load, operational safety, hoists, means of access, derricks, ropes, heat
treatment, vacuum and magnetic lifting gear, attachment of loads, tower cranes and qualification of
operator, signaller etc. See Part 7 of Chapter-28 for their details.
7 UNDERWATER WORKS
Work under or over water is required for deep foundation, well sinking, river dredging,
underwater pipelines, tunnelling, concreting, cofferdam, floating structure and special operations
pertaining to irrigation and marine purposes.
7.1 General Provisions:
Main safety measures necessary are (1) to prevent workers from falling into water (2) to rescue
them in the event of drowning and (3) safe and sufficient transport and life saving equipment.
Life buoys, life jackets, manned boats, fencing, safety nets, safety harness and protection from
reptiles and other animals are also necessary.
Bridges, footbridges, pontoons, walkways, gangways and workplaces should possess sufficient
buoyancy, strength and stability, be wide enough to allow safe movement of workers, free from nails,
bolts, knots and tripping hazards, boarded over, lighted sufficiently, be provided with life saving
equipment, toe-boards, guard-rails, hand ropes etc., be kept clear of tackle, tools and other obstructions,

be made nonslippery by spraying sand, ashes etc., be anchored to prevent run away, be provided with
ladders with safety hoops.
Floating structures should have shelters, lifelines, gaffs, ring buoys. Rafts (logs), if used, should
be strong enough to carry loads, securely moored and have safe means of access.
Iron decks should be studded with non-slip surface and deck openings should be fenced. Floating
pipelines should have safe walkway. No person should enter a hydraulic dredge gear room without
informing the leverman and without being accompanied by a second person. Hoist lines, drag lines,
buckets, cutter heads .and bridles should be inspected daily. Workers should be embarked and
disembarked only at safe and suitable landing places and counted regularly.
7.2 Boats:
Boat used to transport workers by water should comply with legal requirements if any. It should
be manned by an adequate and experienced crew and be equipped with life-saving appliances.
The number of persons that can be transported safely should be marked as clearly visible and no
more person than that must be allowed.
Tow-boats should have a device to quick release tow-rope. Power driven boats should carry
suitable fire extinguishers. Row-boats should carry a spare set of oars. Rescue boats should be properly
constructed and of sufficient length and beam to afford stability. For work in tidal waters or fast flowing
rivers a powerdriven craft should be provided with a fixed selfstarting device on the motor. When not
patrolling, their engines should be run several times a day to ensure full efficiency.
7.3 Rescue and Emergency Procedures:
Buoyancy-aid like life-jackets should be provided to rescue crew. Operatives should not work
alone and they should be trained for emergency procedures.
Rule 36, BOC Workers Rules, 1998, requires emergency action plan to handle emergencies like
drowning of workers, sinking of vessels, fire and explosion, collapse of lifting or transport equipment,
building, shed, structure etc., gas leakage, spillage of dangerous goods, land slide, floods, storing etc. It
should be approved by the Director General.
7.4 Well-Sinking:
Shaft-sinking operation for digging well or tunnel pose various hazards like wet and slippery
footing, cramped working space, insufficient lighting, unknown weakness in rock or soil, handling of
explosives and detonators, hoisting and haulage of muck and accidents due to machinery and mistakes in
working methods. Dewatering pumps, shoring machine guarding and control devices, use of personal
protective equipment, training and supervision are useful remedial measures. 7.5 Cofferdam:
Underwater excavation is carried out by (1) Pumping out the water if inflow is not excessive (2)
Isolating the site by a cofferdam (temporary bund) (3) Sinking caisson (box) with or without compressed
air or (4) Chemical consolidation.

The cofferdam is a temporary structure to exclude water from water-logged soil, river or the sea
to enable the excavation and construction to be carried out in the dry. The cofferdam can be made out of
earth, concrete, sheet piles or sheet cell.
The earthen cofferdam is possible in shallow water with low velocity of current. The earthen bank
is constructed 1 mt of the top water level. Due to water seeping and leaking such dam can fail. Therefore
constant watch is necessary.
Sheetpiled cofferdam can be constructed by using a floating structure with machinery and crew.
All members of floating 'pile-driving crew should be trained to handle boats. The interlocking sheet piles
and bracing in a cellular form are placed through water. Fuel tanks below deck of a floating pile-driving
equipment should be vented to the outside air with flame arresters. Workers handling piles should wear
leather gloves. A competent person should constantly supervise.
After erecting the cofferdam, inside water is pumped out. The excavation is done in dry soil up to
a sound strata, the foundation is laid down and the structure is built. The cofferdam is dismantled
thereafter.
7.6 Caissons:
A caisson is a box type structure to be used as a part of foundation. Unlike cofferdam, it is a

permanent structure and forms an integral part of the bridge or building foundation.
The caissons are of three types (1) A box caisson which is closed at the bottom but open at top to
the atmosphere (2) An open caisson which is open at both the ends and (3) A pneumatic caisson which
has a working chamber with roof in which air pressure is maintained to prevent the entry of water and
soil into excavation.
The box caisson is possible where no much excavation is required under water. The box is
prepared of concrete or stone masonry 6n a dry dock, floated out to the location of sinking, sunk at the
place of foundation bed and filled with mass of concrete or sand.
The open caisson is a hollow cylinder or rectangular hollow shaft made of timber, masonry or
RCC. Its bottom edge is V-shaped (pointed) and known as cutting edge. On reaching foundation level,
mass concrete is placed to plug the cell after which any water is pumped out and further concrete is
placed to form the final seal. Such open caisson is possible on soft soil and not suitable on hard or
irregular rock surface.
Where piles driving or open caisson is not possible, the pneumatic caisson is created by
compressed air to drive water out of the working space for men and voids in material which is being
excavated and thereby making the inside dry for easy working. More than 1 m" or 285 litres of fresh air
per minute per person should be supplied in the chamber at a pressure below 2.5 bar. During compression
initial pressure is kept about 0.25 bar until it is ascertained that no person is feeling discomfort, and
thereafter it may be raised at a rate not exceeding about 0.5 bar/ min. Standby power should be available
to the air compressors. To improve the working condition and to reduce the incidence of caisson sickness,
the air should be warmed in cold weather and cooled in hot weather. In tropical climate, it should be
dehumidified to keep the wet bulb temperature below 25 °C. In air and water tight chamber, openings for
men and materials are provided at top in the vertical shafts with air-locks. The shafts (and openings)
extend from the roof of the caisson to a level well above the water level outside. The man-lock should be
of sufficient size and equipped with pressure gauges, communication system and man-lock attendant.

Every caisson, shaft, working chamber, medical lock and man lock should have a minimum
internal height of 1.8 mt. The door between the working chamber and the man lock leading to a lower
pressure should be kept open when any person is working inside and the lock is not in use. Air supplied
to the caisson from a compressor should be clean and non-polluted. All air lines should be in duplicate
and with non-return valves to prevent the air escape from the chamber if pressure in the lines fails. There
should be a standby compressor for emergencies and two separate power supplies for each compressor.
There should be two independent sources of electrical supply for lighting. Exhaust valves should be
provided on chamber for clearing the air when necessary. Reliable means of communication such as
bells, whistles, telephones etc. should be maintained at all times between the working chamber and
surface installations. An adjustable safety valve should be fitted on the outside of the bulkhead to a
separate pipe leading from the working chamber through the bulkhead to the outside air. Every caisson
and shaft containing flammable material should have water lines, hose connections and fire extinguishers.
In all tunnels 5 mt or over in diameter or height, a well-guarded overhead gangway should be

provided from the working surface to the nearest airlock with an overhead clearance of at least 1.8 mt.
Effects of air pressure on human body may be light (known as bends) or severe resulting in
paralysis or death. Pain in ears, stomach and joints (like rheumatism), profuse cold perspiration,
dizziness, giddiness, double vision, incoherence of speech, heat and feeling of resistance to move owing
to density and pressure of air are reported. Rapid lowering of air pressure (decompression) causes severe
effect as the nitrogen comes out from the body fluid (mostly blood). Therefore it must be ensured that the
depressuring must be carried out slowly.
The workers should be physically fit (not fat, and with normal lungs, kidneys and good heart rate),
above the age of 20 and medically re-examined at least every 2 months or earlier. A first-aid box should
be kept in the working chamber.
To counteract the effect of cold, the air-lock should be warmed, the men coming out (emerging)
should be given hot drink and they should dress warmly. The best cure for 'caisson disease' is
recompression with slow decompression. This is achieved by putting the patient in a medical air-lock for
this purpose. The trained lock keepers and medical lock attendants should be employed in the works. The
medical lock should have two compartments so that it can be entered under pressure.
See Chapter XX, Rule 206 & 207 of the BOC Workers Rules, 1998, for cofferdams and caissons.
8 DEMOLITION
Demolition of very old, life-ended, weak or unsafe construction becomes necessary. Sometimes it
is required for a new construction, alteration, addition or repairs on the same site. High risk is involved
due to falling or flying material, working at height or on a structure being broken, use of heavy hand tools
and heavy blows and vibration or sudden collapse. Not only the workers but the public passing by, have
also to be protected. Proper planning, permit, procedure, sequence of work, training of workers and safety
supervision by a competent person are some of the basic requirements.
See Chapter XII, Rules 108 to 118 of the BOC Workers Rules, 1998, for demolition. See Part 7 of
Chapter-28 for their details.
8.1 Precautions Prior to Demolition :

A definite demolition procedure should be worked after studying the entire structure and carrying
out a survey of its drawings, load bearing members, type of foundation, walls etc., chemical contents if
any, previous use, structural problems, ground characteristics, condition of roof trusses, type of
framing used in framed structure, equipment sensitive to noise, vibration, dust etc., radioactivity, utility
or service lines, gas and power lines, joint with or effect on adjacent building, climatic conditions etc. A
help of structural engineer is advisable.
A method of demolition should be formulated after above survey and recorded in a method
statement after identifying the problems and their solutions.
All electric, gas, water and other service lines should be shut off or safely protected against
damage. The plant or building should be isolated from all other plants or buildings.
For protection of the public, all the roads and open areas surrounding the work (i.e. danger or
safety zone) should be fenced off (fence height at least 2 mt) and caution boards and danger signs should
be displayed in the local language, Hindi and English at prominent places. Unauthorised entry into it shall
be effectively controlled. If a swinging weight (ball) is to be used for demolition, width of the safety zone
should be 1.5 times the height of the structure. If a clamshell bucket is to be used for demolition, safety
zone of 8 mt from the line of travel of the bucket should be maintained.
8.2 Precautions During Demolition :
Only trained workers should be employed (new or unskilled may cause more accidents). They
should wear helmet, safety belt, safety shoes, safety goggles and gloves.
A part which would destroy the stability of other parts should not be demolished. To prevent
danger, parts of structure should be adequately shored; braced or otherwise supported. Foundation walls
serving as retaining walls to support earth or adjoining structures should not be demolished until the
adjoining structure has been underpinned or braced and the earth removed or supported by sheet piling or
sheathing.
Where a deliberate controlled collapse technique is to be used, expert engineering advice should
be obtained. It should be used only where enough surrounding space is available to withdraw men and
equipment at a safe distance. Structure not carrying its design load may be pre-weakened before a
deliberate collapse, but in such cases the pre-weakening should be carefully planned and dead load
should be reduced systematically.
When equipment such as power shovels and bulldozers are used for demolition, type of building,
its dimensions and the power of the equipment should be considered.
Where explosives are used to demolish key members, the blast protection and safe distances
should be agreed in advance. The work should be carried out by experienced personnel in a controlled
manner.
Sometimes catch platforms (at least 1.5 mt wide) are provided along the outside of the outer walls
to catch falling materials. The outer edge of such platform should be higher than the inner edge (i.e.
inclined to wall side) and the platform should be lowered as the demolition work gets lowered. Sequence
of Demolition: Glass panels of doors and windows should be removed first. Then loose objects and
projecting parts including balconies should be removed. Work should start at the top of the structure and
proceed downwards. When work is going on at upper level, workers should not be deployed at lower
level. Broken material should not be thrown but lowered safely. It should not be allowed to be

accumulated to disturb stability. Dusting should be minimised by watering. Stairs with hand railing
should be kept in place as long as practicable to provide access and egress.
Scaffolds used for demolition, should be independent of the structure being demolished.
Travelling mechanical ladders can be used.
AC sheet roofing requires careful consideration of points of support before planning its
demolition. A firm ladder resting on such point should be given to workers to climb to the roof. Then
they should use a cat ladder or a crawling board supported on ridge to stand and remove the sheet. In no
case, they should be allowed to walk or stand directly on the AC sheet. Underneath nearby fall arrester
net should also be used.
Walls should be demolished storey by storey and starting from the top. Unsupported walls should
be prevented from falling by shoring and, ties.
Starting of demolition from the top level
Floors should be demolished by using planking or walkways to stand or move when it becomes
weak to withstand the load. Openings through which material is dropped should be fenced or barricaded.

Tall chimneys should not be demolished by blasting or overturning unless the sufficient open area
is available for its safe fall. Workers should not stand on chimney wall. Thrown down material should be
removed during breaks in the work or under controlled conditions.
Structural steelworks should be demolished by cutting its parts in such a way that it should not
collapse, twist or spring suddenly. It should be demolished tier by tier. Cut parts should not be thrown
from a height. They should be lowered safely.
Industrial structure such as a nuclear power plant, hazardous chemical or petrochemical plant or a
plant containing a plenty of asbestos material (e.g. insulation, AC sheets) should be demolished only after
consulting their respective experts or specialist engineer and taking all precautionary measures against
their specific hazards. General rules are as stated earlier.
9 MOVEMENT OF MATERIALS AND MEN
Construction materials being heavy, long or varying in size, pose hazards in handling, loading,
unloading and transportation. Railway wagons, motor trucks, tractors, trailers etc. are used depending on
the weight, size and distance to be travelled. Training of handling of such materials and use of lifting
appliances for them is a basic requirement. Sec Chapter15 and 16 for material handling and working at
heights and depths. See Part 6,7,8 and 9 of Chapter28 also.
Some general precautions are as under :
1. For selecting transportation by railway wagons, the route should be surveyed. The material should
not foul with any fixed structure object or another wagon while negotiating bend or turn. The
material should not project outside and height should not reach electromagnetic field of overhead
traction line. Railway rules should be followed. Identification, marking and proper packing are
necessary.
2. Motor trucks must have valid RTO permits and efficient brakes, lights, horns, side and reverse
signals, jacks, tools etc. They should be in good working condition. Only trained and licensed
driver should drive and not the helper or cleaner. While driving an Ethylene oxide tanker by a
cleaner, it was dashed against a structure resulting into breaking of the main valve and the whole
factory shed and the tanker were burnt into ashes.
3. Drivers should strictly follow the speed limit on highway and inside any factory premises. They
should observe utmost care while turning, overtaking, crossing railway level crossing and
applying brakes. They should have 'tremcard' while carrying hazardous chemicals.
4. The transport vehicle should not be overloaded. No material should project above or beyond the
side panels. Backward projection should not be more than a meter. Bending bars (rods) should not
touch the road. Liquid should not be leaking. Lime, cement, gravel or dusty material should not
throw continuous dust. They should be covered. Red signals (flag or light) should be displayed on
the projected end.
5. Material should be properly loaded considering weight, dimension, centre of gravity of the load,
carrier capacity, safety distance and working clearance. Load should be properly packed and
lashed. In rainy season, waterproof cover should be provided.
6. Men should not sit on the load or side panels or on the driver's cabin. They should not walk on a
moving vehicle.
Necessary fire fighting arrangement should be kept ready. Engine exhausts shall not open near
any flammable material. Vehicles carrying highly flammable liquids or gases must have spark arrester on
their exhaust pipe. Explosives, detonators and combustible material shall be separately stored with safety

precautions. It should not be piled over 2.5 mt height. See Chapter 13 for fire & explosion safety. For
electrical safety see Chapter II. See Chapter 28, Part 6.1 and 6.2 for Motor Vehicles Act and Rules.
10 HEALTH AND WELFARE OF CONSTRUCTION WORKERS
Occupational hazards and diseases relating to construction work are mainly dust hazards (Silicosis
due to silica dust, Siderosis due to iron dust, Anthracosis due to coal dust and Cement Pneumoconiosis
due to cement dust), noise and vibration, heat and humidity, electricity, hazardous chemicals, work at
heights and depths (in a confined space), material handling, lifting machinery, transport vehicles,
radiation hazards, biological hazards etc. First-aid boxes and occupational health services at workplace
or nearby are most desirable.
10.1 Dust Hazards :
While handling building materials, workers can be exposed to four types of dusts which by
inhalation can cause following lung diseases (Pneumoconiosis) :
Silicosis : Silica (SiO,) dust (respirable size 0.5 to 3 micron) causes fibrotic changes, modulation
in both lungs, shortness of breath, decreased chest expansion, reduced capacity for work and in advanced
case impairment of total lung capacity. The effect is irreversible and no effective treatment is available. It
is a notifiable and compensable disease under the law.
The effect of exposure, varies with the concentration of dust, time period, working conditions,
body resistance, control measures etc.
Chest X-ray shows a snow storm appearance in lung fields. But it should be confirmed by a
history of prolonged exposure of silica dust and symptoms of dry cough, dysponea, chest tightness and
difficulty in breathing. Regular medical examination of workers and engineering controls to minimise
exposure are necessary.
Siderosis is caused by inhalation of iron dust (Iron oxide). Electric arc welding, dry grinding of
iron, buffing, polishing and shot-blasting produce iron dust. It seldom causes serious symptom unless
there is coexistent silicosis.
Anthracosis (Coal workers' pneumoconiosis) is caused by inhalation of coal dust. Foundry

workers, coal handlers, couple collie, boilermen (sealers), furnacemen, railway firemen, graphite workers
etc. are exposed to coal dusts. The first phase (requires about 12 years of work) causes little ventilatory
impairment, but the second phase causes progressive massive fibrosis (PMF) resulting in severe
respiratory disability and tending to death.
Early diagnosis and change in occupation offers the best hope. Other treatment like chemotherapy
should be as per doctor's advice.
Cement (Benign) Pneumoconiosis, silicosis with associated pulmonary tuberculosis, bronchitis

and emphysema are possible with cement or cement and free silica dust (e.g. acid resistant cement).
In addition to these respiratory disorders, other health hazards are as under :

Skin Cement eczema due to alkalinity or presence of chromium Furncles, Pyoderma,
Cellulitis, Asbestosis
Vision Conjunctivitis
Nervous system Muscular pain, Back pain, Neuralgia, Spondylosis, Arthritis and Rheumatism
Digestive system Peptic ulcers
Ear Hearing loss due to high noise
Others Radiant heat, High temperature near furnace, CO gas and Asbestosis due to
asbestos cement products
Prophylaxis (Control measures) are engineering control and medical monitoring.
Engineering control includes methods of elimination or minimisation of dust exposure. Local

exhaust (suction hood), cyclone dust collector, unit dust collector, electrostatic precipitators, substitution
of wet grinding for dry grinding and hydro-blasting for sand blasting and built-in devices with grinding
and polishing machines etc. are generally used. They should be maintained in good working conditions.
Workers should wear dust masks/respirators and eye protection also.
Medical monitoring includes appraisal of dust generating places or processes, area monitoring and
analysis, medical examinations including X-ray and sputum test, lung function test and clinical tests.
See Chapter-24 also.
10.2 Noise and Vibration :
For figures, pictures and detail see Chapter-12.
Crushers, grinders, compressors and heavy lifting machinery in construction industry cause high
noise. Continuously working near such high noise causes hearing loss, deafness, annoyance/change in
heart rate, blood pressure, sweat rate, work performance etc. and also psychological and psychomotor
effects. High frequencies are more serious than low frequencies. Noise level should be kept below 90
decibels by using quieter machinery and processes, enclosures and silencers. If this is not possible,
workers should be given ear plugs or muffs of good quality.
10.3 Heat and Humidity :
For figures, pictures and detail see Chapter-10 and 24.
Steel mills, forge shops, furnaces, boilers, hot asphalt, tar, steam, hot water, damp clay, under-
water work etc. expose heat or humidity.
In dry hot atmosphere, thermal balance can be maintained by evaporation of sweat but in moist
hot atmosphere as in cotton mills, process of perspiration (sweat evaporation) slows down due to
humidity and workers feel great discomfort and their productivity gets down due to heat stress. Main
three types of heat stresses are heat stroke, heat exhaustion and heat cramp.
Insulation of hot processes and parts, lagging of hot pipes, shielding against radiant heat, local
exhaust ventilation, improvement in general (natural or mechanical) ventilation, spot cooling of hot
object, isolation or segregation of hot processes, replacement of workers near furnaces or giving frequent
recesses and adequate supply of drinking water are some of the remedial measures.

10.4 Other Hazards :
Use of solvents, thinners, paints, varnishes etc. cause fire hazards. See Chapter-13 for fire safety.
Use of chemicals, pigments, radioactive substances and biological agents pose peculiar types of hazards.
Their effects and control are explained in Chapter-24. Work permit and special precautions are required
when workers have to work at height or in a confined space. See Chapter 16 for details. For electrical
hazards and controls see Chapter-11.
10.5 First-aid and Health Services :
For figures, pictures and detail see Chapter-26.

At all work sites, first-aid boxes containing prescribed medicines, antidotes and equipment are
most essential. Trained first-aiders should also be employed. They should be proficient in the use of
resuscitation and other life-saving techniques and in rescue procedures. Necessary equipment including
stretchers should be readily available.
All workers should be subject to health surveillance. Work area monitoring should be carried out.
Health services should be available at workplace or nearby. See Chapter-24 for further details.
See Chapter XXIV, Rules 223 to 232 of the BOC Workers Rules, 1998, for medical facilities. It
requires medical examination, construction medical officer, OHC, ambulance room, ambulance van,
stretchers, FAB, emergency treatment, notice of occupational diseases etc.
10.6 Welfare :
At or near work site, adequate supply of drinking water, sanitary and washing facilities or
showers, change or cloak room, lunchroom or canteen, rest room or shelter, facilities for food and drink
and suitable living accommodation should be available to workers. The size and number of such facilities
may vary according to the number of workers. Where necessary separate facilities should be provided for
male and female workers.
See Chapter XXVID, Rules 242 to 247 of the BOC Workers Rules, 1998, for statutory provisions
regarding above welfare facilities.
10.7 Accident Reports and Records :
For statistical tables see Chapter-5 and 19.
Where prescribed, as in case of factory premises, all accidents to construction workers should be
reported to the authorities where absenteeism due to accident lasts for more than 48 hours. All fatal
accidents should also be reported to police and the family of the deceased. Where format is prescribed
(e.g. Form 21, GFR), it must be reported in that form only.
Record of non-reportable accidents including near-misses should be maintained for internal use.
All accidents should be thoroughly investigated by a team of concerned officers including Safety
Officer and their conclusions should be used as remedial measures to prevent future accidents.
Non-factory construction sites should report their accidents to the authorities prescribed.

A good record of all such accidents and their costs should be maintained for a long time. It may
be useful to draft a law or to make internal rules and regulations. See Part 9 of Chapter-5 and Part 3 of
Chapter-19.
Safety Committee should be constituted and a Safety Officer should be appointed in every
establishment wherein 500 or more construction workers are employed as required by Section 38 of the
Building and Other Construction Workers Act, 1996.
See Rule 210, Form XIV for accident report and Rule 230, Form XIII for notice of poisoning or
disease, of the BOC Workers Rules, 1998.
10.8 Ergonomics :
For figures and pictures see Part 3 of Chapter-24.

Different postures while doing construction operations, seat and control arrangement in lifting and
shifting material, equipment and vehicles, use of hand tools etc. require ergonomic considerations.
In a study conducted by NITIE (National Institute of Training for Industrial Engineering,

Bombay), in 1989, on construction workers, 10 different tasks were evaluated for their severity. The tasks
of excavation/digging, plastering, climbing with 15 Kg weight, bending reinforcement bars and
concreting were found to be severe. The energy expenditure for these activities ranged between 8 to 10
Kcal/min and the heart rate between 130 to 150 bpm. Others like casting, painting, mixing cement and
aggregates with water and masonary work were placed in the category of light and moderate work. The
energy expenditure in that case ranged between 2.5 to 8 Kcal/ min and heart rate between 90 to 135 bpm.
In plastering, a stooping posture was found to be harmful. It would be better to adopt a squatting
posture for plastering the wall area below the hip level.
The workers reported acute pain in elbows of the arm holding the working pan. A simple use of a
stool or stand to put the pan can reduce the pain. The use of a longer handle for the patella can be resorted
to reduce stooping.
EXERCISE
1. State, Explain, Mention or Discuss -

1. The reasons for health and safety problems and safety measured based on NITIE study
(1989).
2. The main provisions under the Building and other Construction Workers Act 1996 or
Rules (1998) there under.
3. What are the precautions necessary to run- (1) Crusher plants (2) Power generators (3)
Engines (4) Transport equipment.
4. Safety precautions required for –
(a) Excavation work (b) Drilling, Loading & Blasting (c) Mobile asphalt layers (d)
Crushers plants
5. The safety measures necessary while carrying out tunneling and shaft sinking OR Safety
measures for wall and floor openings.
6. Sequence of demolition OR Precautions during demolition.
7. At length the health and welfare of construction workers.

8. The difference in hazards and control measures while doing under ground, above ground
or under water works.
2. Write Short Notes on –
1. Basic philosophy
2. Dust hazards.
3. Cofferdam.
4. Shoring & Under pinning.
5. Derricks.
6. Precautions prior to demolition
7. Winches or Hoists.
8. Excavators or Road rollers
9. Concrete mixtures
10. Pneumatic compressors
11. Duties of a Construction Safety Officer or a Construction Medical Officer.
12. Role of a Construction Welfare Officer.
13. Ergonomic aspects in construction work.
14. Siderosis or Anthracosis.
15. Caissons or Cast-in-situ concrete structures
16. Site planning and layout OR Precautions for movement of materials and men.
3. “Fall from height and struck by falling objects, are the two major causes of fatal accidents in
construction activity” Justify this statement with statistics or actual case studies.
4. Design a safety work permit at construction site OR A construction safety check-list.
5. Classify the construction machinery and explain in detail any two of them.
6. You are deputed as a construction supervisor for structural steel work and erection. Narrate what
precautions you will observe.
Reference and Recommended Reading
1. Safety and Health in Construction, ILO, Geneva.

2. Safety in Construction Industry, NSC, Mumbai – 22.
3. Safety Manual of Essar Projects Ltd. (EPL).
4. Industrial Safety & Pollution Control Handbook, NSC & ADP.
5. The Building and other Construction Workers Act, 1996 and the Central Rules, 1998.
6. The Factories Act, 1948 and the GFR 1963.
7. Indian Standards on Civil Engineering.
8. Safety and Health in Building and Civil Engineering Work – ILO.
9. Construction Safety Auditing Made Easy : A checklist approach to OSHA Compliacne, Second
Edition by Kathleen Hess- Kosa.
10. Construction Safety Handbook : A practical guide to OSHA Compliance and Injury Prevention,
Second Edition by Mark McGuire Moran.
11. Excavation Safety, A guide to OSHA Compliance and Injury Prevention by Carl O. Morgan.
12. Handbook of OSHA Construction Safety and Health, 2nd Edition.
13. Building Construction by Jha and Sinha, Khanna Publishers, Delhi.
14. Safety in Construction work – Excavations – by HMSO, London.
15. Construction site safety by Hishop.
16. Construction safety and Loss Control by Citelow.


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CHAPTER – 22

Safety in Construction Industry

1. Scope of Safety in Construction work 6.2.2 Cast-in-situ Concrete Structures

1 SCOPE OF SAFETY IN CONSTRUCTION WORK

1.1 Basic Philosophy : 03235213618

Fundamentals of Industrial Safety and Health 22- 1 Safety in Construction Industry

1992 1993 1994 1995 1996

Source : Accident Facts, 1997, NSC, USA.

Year Fatal Accidents

Fundamentals of Industrial Safety and Health 22- 2 Safety in Construction Industry

1. Safety policy statement and strict adherence to it.

12. Parameters of Safety in Construction:

1.2.1 Studies, Statistics and Results :

Fundamentals of Industrial Safety and Health 22- 3 Safety in Construction Industry

1. Motivate their subordinates to attend to safety.

1. The absence of safety rules and regulations.

The main safety measures suggested were

Fall to lower level 324

Fundamentals of Industrial Safety and Health 22- 4 Safety in Construction Industry

Type of Accident Temporary Total Permanent Partial Permanent Total

The reasons of this anomaly, as stated in the article are as under :

1. Gross under-reporting of accidents by Indian industry.

Fundamentals of Industrial Safety and Health 22- 5 Safety in Construction Industry

1. Struck by falling objects, structures, plant, 37.5%

(1) Fall from height and

Therefore safety work to eliminate these causes need first priority.

Fundamentals of Industrial Safety and Health 22- 6 Safety in Construction Industry

This suggests the direction of accident prevention work in construction activity.

1.2.2 Site Planning and Layout :

Refer part 6 and 7 of Chapter 7 for planning, design and layout.

1.2.3 Safe Access :

Fundamentals of Industrial Safety and Health 22- 7 Safety in Construction Industry

1.2.4 Safety Work Permit & Checklist :

A format of such permit is given in Table 22.2.

Table 22.2 : Safety work permit (swp), at construction site Date :

Date : SWP No. : ___________

SWP Requested by / Issued to : Project/ Location of SWP issue SWP Expiry

Description / Nature of Equipment / tools to be Probable Hazards Tick 

Following safety measures/ Following safety measures / Remarks / special instruction if

Fundamentals of Industrial Safety and Health 22- 8 Safety in Construction Industry

A checklist for construction safety is given in Table 22.3.

Table 22.3 Construction Safety Checklist

Name and address of the Construction Company _________________ Working at _________________

No. Checkpoints Comments

Fundamentals of Industrial Safety and Health 22- 9 Safety in Construction Industry

Signature of Auditors _____________________

1.2.5 Good Housekeeping :

See Chapter-8 for details.

Good housekeeping programme should include

Fundamentals of Industrial Safety and Health 22- 10 Safety in Construction Industry

See Parts 6 & 10 of Chapter-23 for other IS. '

Fundamentals of Industrial Safety and Health 22- 11 Safety in Construction Industry

Construction machinery can be classified into three categories as under

1 Lifting Appliances and Gear :

4.1 Lifting Appliances and Gear :

For figures and pictures see Chapter 15.

Fundamentals of Industrial Safety and Health 22- 12 Safety in Construction Industry

Name and address of the Construction Company _ Working at _