MODULE 2

INDUSTRIAL HAZARDS

“Threats to people and life-support systems that arise from the mass production of goods and
services. When these threats exceed human coping capabilities or the absorptive capacities of
environmental systems they give rise to industrial disasters”

“Industrial hazard may be defined as any condition/substance produced by industries may

cause injury or death to personal or loss of product or property”
Occupational hazards include all those work activities and processes involving the worker,
raw materials, and processing activities such as operating machineries and handling
chemicals. The identification of occupational health safety and hygiene hazards has often
come from observations of adverse health effect among workers. Unquestionably it is in the
workplace that the impact of industrial exposures is best understood.
Identification of health and safety problems includes the following:
• Observe workplace

• Investigate complaints from workers

• Examine accident and near-miss records

• Examine sickness figures

• Use simple surveys to ask your co-workers about their health and safety concerns;

• Use check-lists to help you inspect your workplace;

• Learn the results of inspections that are done by the employer, the union or anyone else;

• Read reports or other information about your workplace

Classifications Of Occupational Health, Safety And Hygiene Hazards

i. Physical hazards,

ii. Chemical hazards,

iii. Mechanical hazards,

iv. Electrical hazards,

v. Social hazards,

vi. Biological hazards,

vii. Ergonomic hazards and

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viii. Environmental hazards

I. Physical hazards: Physical hazard has possible cumulative or immediate effects on the
health of employees. Therefore, employers and inspectors should be alert to protect the
workers from adverse physical hazards.
Physical hazard include:
a. Extremes of temperature: The work environment is either comfortable or extremely cold or
hot and uncomfortable. The common physical hazard in most industries is heat. Extreme hot
temperature prevails on those who are working in foundries or in those industries where they
use open fire for energy. Examples of these include soap factories in large industries and in
the informal sectors that use extreme heat to mold iron or process other materials. b. Ionizing
radiation: Radiation is a form of energy. Any electromagnetic or particulate radiation capable
of producing ions is referred to as ionizing radiation. Radioactive materials emit energy that
can damage living tissues.
The types of ionizing radiation with which we will be concerned are:
Electromagnetic
􀂃 X-ray
􀂃 Gamma ray
Particles
􀂃 Neutron, electron, protons
􀂃 Alpha radiation
􀂃 Beta-rays
Radioactive materials can be hazardous in two ways:
1. Those materials that could be hazardous even when they are located some distance away
from the body (external)
2. Others that are hazardous only when they get inside the body by through breathing, eating
or through broken skin (internal)
c. Non ionizing radiation: This is a form of It is electromagnetic radiation with varying
effects on the exposed body depending largely on the particular wavelength of the radiation
involved.
It includes:-
􀂃 Radio transmitters
􀂃 TV
􀂃 Power line
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􀂃 Powerful radio aerials
􀂃 Microwaves
􀂃 Lasers etc.
d. Excessive noise: Noise is defined as unwanted sound. Sound is any pressure variation or a
stimulus that produces a sensory response in the brain. The compression and expansion of air
created when an object vibrates.
II. Chemical hazards: Chemicals are used extensively in industry. Many useful products are
derived from chemicals. Examples are pesticides, fertilizers, paints, plastics and fibre glass.
A chemical accident is the unintentional release of one or more hazardous substances which
could harm human health or the environment. Chemical hazards are systems where chemical
accidents could occur under certain circumstances. Such events include fires, explosions,
leakages or releases of toxic or hazardous materials that can cause people illness, injury,
disability or death.

Hazardous chemicals can be classified into four types of hazards:

• Flammable
• Corrosive
• Reactive
• Toxics (e.g. acute poisons, carcinogens, mutagens, teratogens, etc.)
However, it is important to exercise caution in the usage of chemicals. Some chemicals are
inherently so dangerous that they have to be stored in special containers to avoid contact with
air. Others may appear harmless, but can cause injury almost immediately upon contact. For
many toxic chemicals, the health effects may take a long period of time to develop.
Basically, chemicals may pose one or more of the following hazards: toxic, flammable,
explosive, reactive and radioactive. To assess the hazard potential of a chemical, one should
look not just at the inherent properties such as flammability, toxicity, reactivity or
radioactivity of the chemical but also, the degree of exposure to the users. The latter would
depend on many factors such as the chemical and physical properties, frequency of usage,
amount of materials being used and manner in which such chemicals are handled.

Mechanical hazards

Mechanical hazards are those associated with power-driven machines, whether automated or
manually operated. Failure to provide proper machine guards and enforce their use can be
costly for companies. Mechanical hazards that are not properly guarded are implicated in

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thousands of workplace injuries every year.it is also due to the failure of a mechanical system
due to faulty design, faulty assembly, faulty materials, lack of repair and maintenance.

Electric Hazards

Electrical hazards consist of the following

Shock – Most common and can cause electrocution or muscle contraction leading to
secondary injury which includes falls.
Fires – Enough heat or sparks can ignite combustible materials
Explosions – Electrical spark can ignite vapors in the air
Arc Flash - can cause burns ranging from 14,000 degrees f. to 35,000 degrees f
Arc Blast – In a short circuit event copper can expand 67,000 times. The expansion causes a
pressure wave. Air also expands adding to the pressure wave
Envionmental Hazards

Environmental Hazards Consists Of The Following

Air Contaminants

Land And Climate Related Hazards

Physical Hazards

Chemical Hazards

Biological Hazards

Social & Psycological Hazards

Social & Psycological Hazards Consists Of The Following

Fatigue
Shiftwork
Stress
Bullying In The Workplace
Workplace Violence
INDUSTRIAL SAFETY TRAINING
With an emphasis on each trainee's role and responsibility in developing a more complete
knowledge of, and appreciation for, workplace safety, the industrial safety training program
provides employees with specific procedures for handling various materials, operating

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different kinds of machinery, and performing various tasks safely while at the same time
ensuring maximum organizational productivity.
Employers must have an overall safety program including relative site specific safety
information where applicable. The safety training program should cover topics such as:
Accident prevention and safety promotion

Safety compliance

Accident and emergency response

Personal protective equipment

Safety practices

Equipment and machinery

Chemical and hazardous materials safety

Workplace hazards

Employee involvement

Those who are new on the job have a higher rate of accidents and injuries than more
experienced workers. If ignorance of specific job hazards and of proper work practices is
even partly to blame for this higher injury rate, then training will help to provide a solution.
The Management should evaluate or verify that employees comprehend the training given to
them. This means that the training to be given must have established goals and objectives
regarding what are to be accomplished. Subsequent to the training, an evaluation would be
conducted to verify that the employees understood the subjects presented or acquired the
desired skills. If the established goals and objectives of the training program were not
achieved as expected, the employer then would revise the training program to make it more
effective, or conduct more frequent refresher training or some combination of these.

Benefits of a training program

An effective training program can reduce the number of injuries and deaths, property
damage, legal liability, illnesses, workers' compensation claims, and missed time from work.
An effective safety training program can also help a trainer keep the required mandated safety
training courses organized and up-to-date.
Safety training classes help establish a safety culture in which employees themselves help
promote proper safety procedures while on the job. It is important that new employees be

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properly trained and embraces the importance of workplace safety as it is easy for seasoned
workers to negatively influence the new hires. That negative influence however, can be
purged (removed) with the establishment of new, hands-on, innovative effective safety
training which will ultimately lead to an effective safety culture. The role of training in
developing and maintaining effective hazard control activities is a proven and successful
method of intervention.
An employer is required to train employees in the safety and health aspects of their jobs. It is
the employer’s responsibility to limit certain job assignments to employees who are
“certified,” “competent,” or “qualified”—meaning that they have had special previous
training, in or out of the workplace. The term “designated” personnel means selected or
assigned by the employer or the employer’s representative as being qualified to perform
specific duties.
Ergonomics
Ergonomics is the study of how a workplace, the equipment used there and the work
environment itself can best be designed for comfort, efficiency, safety and productivity. Often
we can improve our levels of comfort and productivity with relatively simple changes.
Ergonomics is the science of fitting jobs to people. Ergonomics is derived from the Greek
language Ergon means work and Nomos means laws, so ergonomics means work laws.
Ergonomics encompasses knowledge about physical abilities and limitations, as well as other
human characteristics, that are relevant to job design. An ergonomic hazard is a physical factor
within the environment that harms the musculoskeletal system. Ergonomic hazards include
themes such as repetitive movement, manual handling, workplace/job/task design,
uncomfortable workstation height and poor body positioning.

Although ergonomics is a broad field, the main areas of concern for workplaces and
employees will often relate to:

• workstations (sitting and standing)

• equipment layout and operation
• computer systems
• noise
• lighting
• thermal comfort
• Maintenance tasks performed on plant items.

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Ergonomic issues can be associated with a wide range of concerns including the physical
design of workstations, workspaces, the working environment, tools, vehicles, computer
programs and plant. It can also involve cognitive processes such as those involved with
workload, decision making, skilled performance and stress.

Objectives of Ergonomics
1) To optimise the integration of man and machine in order to increase productivity with
accuracy
2) To take care of the factors governing the physical and mental strain (i.e. fatigue) so as
to get maximum satisfaction for the worker which at the same time enhances the
productivity
3) Attempts to minimize the risk of injury, illness, accidents and errors without
compromising productivity.
4) To improve the design of machine at the initial design stage or later whenever the
existing product or process is modified.

Advantages Of Ergonomics

1 Increased savings

2 Fewer employees experiencing pain

3 Increased productivity

4 Increased morale

5 Reduced absenteeism

Musculoskeletal Disorders

Musculoskeletal Disorders or MSDs are injuries and disorders that affect the human body’s
movement or musculoskeletal system (i.e. muscles, tendons, ligaments, nerves, discs, blood
vessels, etc.). When a worker is exposed to MSD risk factors, they begin to fatigue. When
fatigue outruns their body’s recovery system, they develop a musculoskeletal imbalance. Over
time, as fatigue continues to outrun recovery and the musculoskeletal imbalance persists, a
musculoskeletal disorder develops. We use the term “musculoskeletal disorder” because it
accurately describes the problem. Other common names for MSDs are “repetitive motion

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injury”, “repetitive stress injury”, “overuse injury” and many more. The problem with using
that kind of terminology is that it implicates a singular cause for damage to the musculoskeletal
system – repetition and stress. This is limiting because more and more research is pointing to
multiple causative risk factors leading to MSDs.

Musculoskeletal disorders, or MSDs, are injuries or illnesses to soft body tissue such as:
• Muscles
• Nerves
• Tendons
• Ligaments
• Joints
• Cartilage
• Spinal Discs
The Musculoskeletal System includes the following:

1. Bones – The load-bearing structure of the body

2. Muscles- Tissue that contract to create movement

3. Tendons – Tissues that connect muscles to bones

4. Ligaments – Tissues that connect bones to bones

5. Cartilage – Tissue that provides cushioning and reduces friction between bones

6. Nerves – Communication system that links muscles, tendons and other tissue with the
brain

7. Blood Vessels – Tubes that circulate nutrients throughout the body

MSDs-Carpal Tunnel Syndrome (CTS)

Carpal Tunnel is a tunnel in the wrist through which the median nerve and nine digital flexor
tendons pass. It is formed by the wrist bones and a dense trans-carpal ligament. Continued
and repetitive pressure on the median nerve in the carpal tunnel can cause CTS.

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Carpal Tunnel

Due to the Compression of the median nerve at the wrist. As a result of the Tunnel made up of
nine flexor tendons and one peripheral nerve. Numbness and tingling on the thumb side of the
hand

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MSDs- Back Injuries

Common causes

Heavy lifting from above the shoulders

• Heavy lifting from below the knees

• Twisting while lifting/carrying

• Bending over at the waist

• Carrying objects to one side

MSDs-Joint Disorders
Joints include many structures, such as tendons, muscles, nerves and bones. Inflammation
may be caused by joint damage or repetitive, heavy use. With inadequate repair, cartilage
thinning may lead to osteoarthritis.

Cumulative trauma disorder

A cumulative trauma disorder, also known as CTD, is defined as the excessive wear and tear
on tendons, muscles and sensitive nerve tissue caused by continuous use over an extended
period of time. CTDs can develop from improper work positioning, repetition or force.

The three main risk factors found in computer workstation environments that can lead to
CTDs are:

• Awkward posture and position such as bent wrists, elbows held away from the body,
outstretched arms or slumped shoulders
• Repetitive action from typing, keying and sorting operations
• Use of excessive force when typing

These risk factors can be controlled by adjusting the workstation, varying worker position,
reducing continuous or repetitious actions, and periodically stretching throughout the day.
Employers should design workstations to reduce or eliminate bad ergonomic exposures. A
neutral work position can be obtained by adjusting the worker’s desk and chair height, as well
as keyboard position.

Key elements to consider for an ergonomic computer workstation include:

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 • Invest in a good chair that can be adjusted several ways. The seat height should be set
so that thighs are nearly parallel with the floor and feet rest flat on the floor. The chair
back should adjust and provide lumbar support.
• Make sure a monitor’s casing is 2-3 inches above eye level, centred and
approximately 18-30 inches from the face.
• Take steps to reduce glare on the screen.
• Use a document holder next to the computer screen. Place it at the same height and
distance from the worker’s face as the screen.
• Keep wrists flat and straight in relation to the forearms and centered to the body when
using a keyboard and mouse.
• Relax the arms and elbows, keeping them close to the body.
• Place adjustable keyboards so they form an approximate 90-degree angle at the
elbow.
• Take frequent and short breaks to stretch the hands and fingers and to rest the eyes.
Try to focus on an object several feet away. Move eyes in all directions.
• Position work equipment so the most-frequently used items are within comfortable
reach.
• Use a telephone headset to free up hands and prevent cradling of the phone.

The appropriate placement of the components and accessories for a computer workstation
will allow workers to maintain neutral body positions, perform more efficiently and work
more comfortably. Although no single “correct” posture or arrangement of components will
fit everyone, basic ergonomic design initiatives can improve workers’ ergonomic positioning
to help eliminate or lessen the potential for CTDs.

SAFETY COMMITTEE

The primary purpose of the Safety Committee is to promote safety awareness and reduce the
potential for injury/loss throughout a Manufacturing Company.
The Safety Committee is to be chaired by the Safety Director and include representatives
from each department (total number of committee members not to exceed five individuals).
Members can be volunteers or appointed. Membership is limited to two terms (1 year each)
during any four year period.

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Meetings are to be scheduled, when possible, for the same day each month. All meetings are
to take place in the conference room. Each meeting should have a set agenda and minutes of
each meeting recorded. A copy of the minutes shall be forwarded to the Executive Vice-
President within 48 hours of meeting.
Each Safety Committee Meeting shall include a review of the prior month’s minutes as well
as a review of the prior month’s injury/illness log and investigations of losses/claims. Past
injuries/claims/losses need to be reviewed for any patterns or trends.
General functions of the Safety Committee can include:
(1) Identifying workplace hazards
(2) Enforcement of Safety Rules
(3) Measuring safety performance
(4) Reducing frequency/severity of injuries
(5) Creating safety policies
(6) Developing and monitoring safety programs
Specific tasks of the Safety Committee can include:
(1) Conducting self-inspections of the workplace
(2) Review employee reports of hazards
(3) Assist in safety training
(4) Creating safety incentive programs
(5) Publish/distribute safety newsletter
(6) Inspect PPE (Personal Protective Equipment)
(7) Post safety posters/slogans on bulletin board
(8) Identify Light Duty Jobs

Importance of Industrial safety

Workplace safety is very important for each and every employee in the industry because all
the workers desire to work in a safe and protected atmosphere. Health and safety is the key
factor for all the industries in order to promote the wellness of both employees and employers.
It is a duty and moral responsibility of the company to look after the employee’s protection.

Each and every person who leaves his home for his work in the morning should come back to
his home in evening in good health. These days, workplace health and safety procedures are

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important for the well-being of both employees and employers because human loss is
immeasurable and intolerable. As, such loss or injuries can employ major loss to the families.

All the industries do have safety risks but the management should devote their time to think
and strategize the things that what safety precautions are required in their company to make
sure that their workers are safe enough for all the time. Also, the management should confirm
with all the workers related to their daily work and comfort. So, that the management can take
the same step according to the desired aspects of workers. This helps them in improving the
productivity and quality of the products and lot more.

1. Aware about the surroundings: There are many employees who doesn’t bother about
their surrounding hazards. But, it is important to observe your co-employees working
circumstances. Once you get to know about the particular hazards that occur at your
workplace, then it will help you in reducing the risk and allow you to take the precautionary
steps.

2. Reduce workplace stress: Most of the employees are not fit and healthy because of their
busy schedule, which includes long working hours, work-pressure and conflicts occur with co-
workers or with the boss of the organization. And, all these can lead to some illness or
depression to the employees. Also, this not only affects their professional life but also creates
the nuisance in their personal lives too. So, instead of waiting to get unfit, it is better that you
start take care of your health, by taking regular breaks, sit in an appropriate posture with
appropriate diet. It will be better for you to schedule your work accordingly and manage the
things to reduce your workplace stress.

3. Use tools appropriately: Take appropriate precautions while using machinery or any other
tool, instead of taking any shortcuts. Taking shortcuts is one of the biggest reason behind
workplace loss. It’s a biggest safety risk to use scaffolding as a ladder or one tool instead of
another for a particular job. So, it is always recommended to use the correct tools and reduce
the opportunity of workplace injury.

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4. Keep crisis exits which are easily accessible: In case there is an emergency, you will need
quick access to the exits. It is also advised to keep clear usage of equipment shutoffs which
might stop you from performing at emergency.

5. Update Your Supervisor about the unsafe conditions: It is important that you keep
updating your supervisor about the hazards or risks occur at workplace. They should be legally
obligated to ensure that their employees are working a safe environment or not. And, in case,
if the employees are not working in safe conditions, then it is the responsibility of the
supervisor to listen and understand their condition and create safe working environment for
employees.

6. Use mechanical assistance: Whenever, you want to carry or lift up some heavy
equipment’s then you should use a conveyor belt, crank or forklift. There are lot of risks
involved, if you try to lift something which is heavier, it can affect your weighing capability
and can lead to some muscle displacement. So, make sure that use the appropriate tools for not
harming yourself.

7. Stay Alert: There are many employees who usually compromise or ignore the alerts of
advance warning and due to this, a number of workplace injuries or fatalities occur.

8. Reduce Workplace Environment Stress: Stress to any employee or to any co-worker, can
lead into depression and into concentration problems. And the main reason includes, extended
working hours, excess of work, insecurity of job and issues which occur at co-workers or
professionals. So, instead of taking stress on your shoulders, you should discuss it with your
supervisor and ask him/her to look after your problems which you are facing in the
organization.

9. Wear the right safety equipment’s: It is essential that you wear the right protection
equipment tools during your work. And, the equipment’s can be in any form like, earplugs,
earmuffs, hard hats, gloves, full-face masks, safety gloves and any other equipment which is
required to wear while working. These tools will prevent the workers from the incidents that
occur at workplace.

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10. Sit in a proper posture: If have a sitting job, then it is essential than keep your posture
correct, while working on a desk. You need to keep your shoulders in line and straight back to
avoid any spine problem. Try to ignore stooping and twisting regularly and if possible, then
try to use the comfort designed furniture and the safety equipment’s, so that the desired things
will be in your reach.

Safety is one of the biggest issue and it is completely the responsibility of the mangers and the
business owners to make sure that their employees are working in safe environment or not.
The management should make sure that they keep on motivating and boosting the employees
to make them active in the working process.

There should be an appropriate discussions done about the work and the culture of the office
on regular intervals, so that the management remain aware that how they simplify the things
for the employee’s comfort. Also, to motivate the workers, management should provide
rewards as an appreciation towards their work. Thus, these only steps will make your
workplace very secure and safe for the employees to work.

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