Professional Documents
Culture Documents
HSEmanual PDF
HSEmanual PDF
E & C Division
E & C DIVISION
Contents
1. Introduction
2. SHE Policy
3. SHE organisation and Management
3.1. Management Commitment
3.1.1. Site commitment
3.2. SHE Organisation
3.2.1. Safety Control - Organisation Chart
3.2.2. Site Safety Organisation Chart
3.2.3. Duties and Responsibilities
3.2.3.1. Management
3.2.3.2. Safety Control Department
3.2.3.3. Resident Construction Manager
3.2.3.4. Site Engineer
3.2.3.5. Site Safety Officer
3.2.4. Returns
3.2.4.1. Site Opening / Closing Report
3.2.4.2. Monthly Reports
3.2.4.2.1. Monthly statistics report
3.2.5. Positive Reporting
3.2.5.1. Format
3.2.6. Daily Log – Book
3.2.6.1. Format
3.2.7. Safety Promotion and Recognition
3.2.7.1 Display Board of Safety Performance
3.2.7.2 Recognition
3.3. Statutory Requirements
3.4. Pre qualification for Selection and Performance of Contractors –
for L & T work.
Contents 1
E & C Division SHE Manual
Contents 2
E & C Division SHE Manual
7. Mechanical Works
7.1 Manual Handling
7.1.1 Winch
7.1.2 Reeving
7.1.3 Rigging Procedure and Precautions
7.1.4 Test Certificates
7.1.5 Operators & Banksman
7.1.6 Safe working load for men and women.
7.2 Crane Safety
7.3 Erection of Structures
7.4 Use, Care and Maintenance of Slings
7.4.1 Synthetic Ropes / Slings
7.4.2 Wire Ropes
7.4.3 Lifting Gears – Hooks, Shackles etc
7.5 Hoists
7.6 Other mobile machinery and their movement at the site
8. Critical Jobs:
8.1 Work over water
8.2 Confined Space
9 Welding and Gas Cutting
10 Health and Hygiene
10.1 Work Environment
10.1.1 Noise and Vibration
10.1.2 Lighting
10.1.3 Ventilation ( Heat Stress )
10.2 Personal Protective Equipment
Contents 3
E & C Division SHE Manual
Contents 4
FOREWORD
The need for a SHE manual for those engaged in or concerned with
construction activity was recognized during the activities of Business
Specific initiatives for safety Assurance by the senior management.
J.B.Desai
Dy.General Manager
Safety Control. E & C Div.
E & C Division SHE Manual
1. Introduction
Introduction 1
LARSEN & TOUBRO LIMITED
Engineering & Construction Division
CORPORATE POLICY
1. To Engineer and Execute projects with consistent quality, cost and delivery in line with
the requirements of our customers, and to exceed or meet their expectations, whilst
enhancing our shareholder value.
2. To set and review quality objectives for Continual Improvement of our products and services,
whilst implementing the globally recognised management systems for Quality, Safety,
Environment and Information Technology, and integrating these systems with our business
partners and customers.
3. To design / operate and maintain safe and environmentally friendly plants which meet all
applicable statutory and regulatory requirements.
4. To advance / ensure the use of better and cleaner technology to minimise adverse
environmental impacts.
7. To comply with all applicable occupational Health & Safety legislation and continually
improve safe working practices through setting health and safety objectives and
ensure good health, safety and security of all our people, our biggest asset.
9. To promote a culture of mutual trust, caring and sharing achievements, with our people,
our society, our stakeholders and our customers for the growth and benefit of our
Nation.
10. As an undisputed leader in the Indian context, we continue to make things that make
India proud, and shall strive to be amongst the globally outstanding companies, which
the World is proud of.
__________________________
Date: 3rd May, 2000 K. VENKATARAMANAN
(Member of the Board & Sr. VP)
E & C Division SHE Manual
SAFETY COMMITMENT
Cluster Heads
Chief
(Management
Services) Business
Group Leaders
Head
(Project Management/ER&C)
Head
(Safety)
Resident
Construction Managers
LEGEND
: Communication / Interaction
Head
(Safety)
Safety
Engineers
Resident
Construction Managers
Site Safety
Officers
3.2.3.1. Management
3.2.4. Returns
3.2.4.1.1. Objective
3.2.4.1.2. Procedure
3.2.4.1.3. Definitions
3.2.4.1.5 RECORD
Forms Records
Site opening and closing Report CSC – 10 –R2
Annexure -1
4. Complete address
Name : ________________________________
(Project Execution Manager/ Resident Construction Manager)
Copies to :
: All SBU Heads
: Project Execution Manager - Powai/ Baroda
: Champion of concerned SBU
Annexure 2
Name : _____________________
(Project Execution Manager/
Resident Construction Manager)
Copies to:
: All SBU Heads
: Project Execution Manager - Powai/ Baroda
: Champion of concerned SBU
3.2.4.2.1. Objective
3.2.4.2.2. Procedure
3.2.4.2.2.1. SSO shall write the correct Accident Data & Man – Hours as
per the standard format given by Safety Control Dept. E &
C Division.
3.2.4.2.2.2. SSO & RCM shall sign report. If RCM is not present, his
representative will have to sign and to be forwarded to
Safety Control Dept. in the first week of every month.
3.2.4.2.2.3. Monthly statistic report are processed and analysed by
Safety Control Dept. and performance is evaluated for
further action. Also it will be published in quarterly safety
bulletin.
3.2.4.2.3 Administration
3.2.4.2.4 Clarification
3.2.4.2.5 RECORD
Form Reference
3.2.4.2.5.1 Monthly Statistic Report - CSC-02-R1
No. of People
Man hours worked
O.T hours
Total Man hours
Grand total of man hours worked during the month ( A + B + C ) :
Cumulative man-hours ( from _________1999 to _________2000) :
( Since the opening of site )
_____________________________ __________________
Signature of Site Safety Officer Signature of RCM
Date: Date :
Note: 1. Report should be legible, properly typed. Copy distribution : 1. Site Safety Officer
2. Standard 48,000 man hours lost is taken 2. Site in charge contractor through RCM
for any fatal accidents as per IS No. 3786-1983. 3. DGM, E & C Division Safety, Powai
3. Reportable accident report is to be sent 4. DGM QAIS Process Cluster Baroda
within 24 hours of occurrence. 5. BUH Powai or Baroda / Champion
6. Head Construction Baroda / Powai
E & C Division SHE Manual
3.2.5.1. Objective
3.2.5.2. Procedure
3.2.5.3. Administration
Annexure
Name of Site :
Ref. :
Date :
From :
We shall ensure that this measure/practice will continue until the site is
closed.
_____________________ __________________________
Site Safety Officer Resident Construction
manager / engineer
Name: Name:
Annexure
SR.
DATE OBSERVATIONS ACTION TAKEN SIGN OF SSO SIGN OF RCM
NO
3.2.7.1.1. Objective
3.2.7.1.2. Procedure
3.2.7.1.6. Administration
A A A
Y Y Y
Annexure
S S S
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(A) Objective
(B) PROCEDURE
In any case, the original must come to Head – Safety Control and
others retain copies.
3. Safety Control Engineer (SCE) from Safety Control scrutinises the
information and visits the contractor office / sites for inspection, if he
finds more than 80 % of the requirements are met . SCE advises the
contractor about the shortfalls, if any.
4. If 80 % requirements not met, Head – Safety Control reject the
contractor’ s application to register and asks him to resubmit when is
ready to meet the requirements. If the contractor intends to know,
Head – Safety Control will inform the contractor in writing about his
shortcomings in safety qualification.
5. If the contractor qualifies,
- Head – Safety Control will inform the contractor about his
acceptance by L&T for registration.
- Head Safety Control will inform all BUH’s / DGM’s / AGM’s / PM’s
/ SM’s by a memo and a copy of updated list of prequalified
contractors.
6. If during the site inspection of SCE , any shortfall in the qualified
contractor safety capability is observed , he will be instructed to
corect it within a specified time , failing which he will be disqualified.
Then
- Head – Safety Control will inform the contractor about his
disqualification.
- Head – Safety Control will inform all BUH’s / DGM’s / AGM’s /
PM’s / SM’s by a memo and a copy of updated list of prequalified
contractors. Name of the disqualified conractor will be deleted in
this list.
It will be decision & responsibility of PM / SM about the continuation
of services of the subject contractor at the ongoing sites. In any
case, the contractor shall not be awarded any new contract for
work/services, untill he requalifies in safety.
1. Project / Site Manager will send the CSCE form along with other
documents of RFQ , to all prospective contractors, who are not
qualified in Safety with L & T E & C Division.
2. When PM / SM receives the filled - in CSCE , he will send original to
DGM ( QA & I ), retaining a copy of the same.
1. All such contractors , who are desirous of working at L & T site, within
one year , are informed by PM / SM about L & T’s requirement for pre-
qualification in SAFETY.
2. Same as in Procedure No. CSC-03/1.
3. Same as in Procedure No. CSC-03/1.
4. Same as in Procedure No. CSC-03/1.
5. Same as in Procedure No. CSC-03/1.
(C) Administration
(a) Books containing 5 sets of CSCE Forms will be sent to all sites
by Safety Control Department . More forms can be obtained
from Safety Control Department. However, if forms are
exhausted, the CSCE should be prepared in photocopy/typed
copy and submitted to Head Safety Control.
(b) SE will periodically check at all E & C Division Sites whether the
contractors working at sites are qualified in Safety by L & T
and advise Sr. V. P. / BUH’ s about the status every quarter.
(A) Objective
(B) Procedure
(C) Administration
SCOPE OF APPROVAL
THE SCOPE OF APPROVAL DETERMINES THE NATURE OF YOUR SERVICES YOU INTEND TO PROVIDE TO L&T
SECTION C – SAFETY ORGANISATION
1. Do you provide safety officers at your job sites? Yes / No
Give details, no. of safety officers, their qualifications, their accountability and authrities, their nature of work. (Full-time or Part-
time?)
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
2. Do you nominate trained safety observers among workmen at your job-sites? Yes / No
3. Do you have formal / written accident (personal & equipment) reporting & investigation system? Give details and attach blank
forms used in your company. How does the system work?
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
4. Do you keep records of all accidents, mishaps, dangerous occurrences at all your job-sites?
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
e. Other dangerous
occurrences (describe) _____ _____________ ________________ _________________
3. Was your company / company official involved in any litigation due to accident / fire etc. at your job sites in the last three years?
Is there any court case pending against your company / company official? Give details.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
SECTION F – YOUR PROPOSAL FOR THE SPECIFIC JOB-SITE FOR WHICH ARE BIDDING TO L&T
1. Give details of insurance, legal arrangement etc. you will provide / have provided for in this bid.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
2. Will you indemnify L&T and its personnel against any legal action due to accident, fire, dangerous occurrence at L&T site & its
surroundings? Give details.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
E & C Division SHE Manual
3.5.1. Introduction:
Statutorily (See section 38 of The Building and other construction
workers (Regulation of employment and condition of service) Act
1996) each site should have a safety committee having equaled
number of representatives from management and workers/
contractors. A well-planned safety committee is a great motivator
for safety. It’s primary purpose is to enable management and
workers to work together to monitor the site safety plan, so as to
prevent accidents and improve working conditions on site. Its
size and membership will depend on the size and nature of the
site and upon differing legal and social conditions in the state
concerned, but it should always be an action orientated group of
people in which both management and workers are represented.
The safety committee carrying out a site inspection together
raises the level of safety consciousness at the site.
Annexure
2) Meeting Frequency
4) Administration
Present
Sr.
Name Company Signature
No.
___________________________ ____________________
Name & Signature of Site Safety Officer Name & Signature of RCM/RCE
Date: Date :
Note: Copy Distribution: 1. Site Notice Board
1. Report should be legible, properly typed. 2. All committee member
3. SCD – Powai
4. Project Manager
5. Safety Champions
(A) Objective
(B) Procedure
3. Technical discussions with (a) Obtain sections (7) & (8) Marketing
the Client of CSP duly filled up,
from the Client prior to
the technical discussions.
(D) Administration
(E) Definitions
(A) Objective
(B) Definitions
(a) Immediate loss of any part of the body or any limb or part
there of.
(b) Crushed or serious injury to any part of the body due to which
loss of the same is obvious.
(c) Any injury which is likely to prove fatal.
(d) Unconsciousness due to accident.
(e) Severe burns or scalds due to chemicals, steam or any other
cause.
Dangerous Occurrences:
Minor Injury:
(C) Procedure
(D) Administration
(E) Records
Form Reference
1. Accident Report CSC-01-R1-AR.
2. Accident Investigation CSC-01-R1-AI.
3. Near miss Accident Report CSC-01-R1-NA.
4. First Aid Accident Report CSC-01-R0-FAAR.
Project Name & Job no. Exact location of Accident / Incident Date & Time of Incident SBU
Specify the injury, extent of damage / loss Location of Injury Object causing injury
( e.g. Fatal, loss of fingers, fracture of leg, scald etc. ) ( e.g. right leg, left hand, left eye etc. ) ( e.g. structural material., m/c, tools etc. )
Whether there was any unsafe condition Whether any unsafe act by injured person
Yes ! No ! Yes ! No !
Whether the person was wearing protective equipment Was he under the influence of Alcohol / Drugs
Yes ! No ! Yes ! No !
If Yes, relevant PPE used :
Whether medical aid was given Has report been given to authorities
Yes ! No ! Yes ! No !
Whether person was hospitalised If Yes, to whom ( Specify ) :
Yes ! No !
Probable cause of Accident & any additional information :
Name & designation of investigating person Project name & Job no. Exact location of Incident
Name of Injured Designation & Token no. Age : _____ Date & Time of Accident
Sex : _____
Accident details ( CSC-01-R1-Accident Report (AR) No. ___________)
State whether it is Personal Injury / Property damage Whether LTA or Minor or Others Name of Contractor
( Specify value in Rs. )
Cause of Accident
What immediate actions have been taken to prevent such What actions could be taken to prevent such
accidents : accidents in future :
Whether the unsafe practice / Act / Condition was informed to the person/s involved or contractor supervisor or L&T
engineer before filling the form : ! Yes ! No
To whom reported ( Give name of persons ) :
Name of the reporter with whom he is working / SSO L&T site manger’s remarks
________________________________________
Name
2.
3.
2. 2.
3. 3.
____________________________________ ____________________________________
NAME OF REPORTING SUPERVISOR / SSO NAME OF RCM
___________ ___________
DATE: SIGNATURE DATE: SIGNATURE
Copy distribution : 1. Site Safety Officer
Note : 1. Please attach sketches or a separate sheet if space for 2. Site in charge contractor through RCM
any column is not adequate. 3. DGM, E & C Division Safety, Powai
2. Report should be legible, properly typed.
4. DGM QAIS Process Cluster Baroda
3. The purpose of first aid report is to find out the causes, not
to fix blame on somebody. 5. BUH Powai or Baroda / Champion
4. Only those name shall be included who received only 6. Head Construction Baroda / Powai
first aid injury & resume duty within 2 hours.
E & C Division SHE Manual
(B) Procedure
(C) Administration
Introduction
Training Needs
Program Objectives
Annexure 1
• Safety philosophy
• Material handling
• Crane safety
• Fire safety
Annexure - 2
Session 1
Safety and The Supervisor
Safety and efficient production go together.
Accidents affect morale and public relations.
The cities of a supervisor under OSHA.
Session 2
Know Your Accident Problems
Elements of an accident. Unsafe acts, unsafe
conditions, accident investigations, measurements
of a safety performance. Accident costs.
Session 3
Human Relations
Motivation. Basic needs of workers.
The supervisor as a leader.
The alcohol and drug problem.
Session 4
Maintaining Interest in Safety
Committee functions, maintaining good
employee relations. The supervisor’s role in off-
the-job safety.
Session 5
Instruction for Safety
Importance of job instruction. Making a job
Safety analysis (JSA). Job instruction training (JIT).
Session 6
Industrial Hygiene
Environment health hazards. Skin diseases.
Lighting, noise, ventilation, temperature effects.
Session 7
Personal Protective Equipment
Eye protection, face protection, foot and leg
Protection, hand protection. Respiratory protective
Equipment. Protection against ionizing radiation.
Session 8
Industrial Housekeeping
Results of good housekeeping. The responsibility
of the supervisor. OSHA requirement.
Session 9
Material Handling and Storage
Lifting and carrying, handling specific shapes.
Hand tools for material handling. Motorized
equipment. Hazardous liquids and compressed gases.
Session 10
Guarding Machines and Mechanisms
Principles of guarding. Benefits of good guarding.
Types of guards. Standards and codes. OSHA regulations.
Session 11
Hand and Portable Power Tools
Selection and storage. Training in the safe care
Objectives :
Procedure :
This procedure lays down steps to be taken by RCM/ RCE before and
during the above mentioned activities at construction site.
There are five different ‘Permit’ forms, each dealing with one of the five
activities mentioned above. Each form has certain standard instructions
and space for writing special instructions by RCM/ RCE, related to the
activity and site situation. These instructions have to be clearly
understood by the workers, Manager/ Engineer/ Supervisor and ensured
that they are followed by the persons actually carrying out the concerned
activity. The forms, therefore, require signatures of concerned responsible
persons, implying their commitment to the instructions. The forms also
require communication regarding completion of the ‘permitted’ activities.
After a form is returned stating completion of an activity, the same can
not be carried out again unless the permit is renewed. The permit can be
renewed for maximum 6 days only. Thereafter a fresh permit is required.
Annexure - I to this procedure lists construction activities that require
issue of permits.
Adminstration
RCM/ RCE shall ensure that this procedure is followed as outlined below:
1. RCM/RCE shall inform all contractors about the permit system and
advise them in writing (by letters and notices) that permits are
required to carry out the above mentioned five activities.
3. RCM/ RCE shall issue the requisite permit form noting down special
instructions and if instructions, if any to the contractor’s supervisor,
who will sign on the form as the ‘Initiator’.
4. After the site and persons are ready as per the instructions on the
form, RCM/RCE, shall inspect the work-site and persons for
compliance of the instructions and if instructions are fully complied,
the contractor’s supervisor, RCM/RCE, L&T Engineer and SSO shall
sign the form to permit the form to permit the activity for the period
and date mentioned on the form.
immediately by stating the reason and signing the permit, if they find
any deviations during the progress of work. The same activity can be
carried out again by obtaining a fresh permit from RCM/ RCE.
11. All signatures and notings of the forms shall be done on both ‘Red’
and ‘Yellow’ copies of the form.
12. Samples of the forms for the said five permits are annexed to this
Procedure.
13. Safety Control Department (SCD) will print and send 100 nos. of
each form to all new and on- going sites, before the effective date of
this Procedure. RCM/ RCE shall promptly and well in time request
additional forms to SCD, when required or may get them printed
without any change in the contents of the form.
RCM/ RCE may use photo copies of the blank forms if the originals
are not available, due to unavoidable delays.
14. RCM/ RCE shall ensure that under no normal circumstances, the said
five activities / work shall be carried out by contractors without a
valid permit.
15. RCM/ RCE shall inform SCD, if there is a need for an additional ‘
permit’ for activities which are not concerned in this ‘ Permit System’
and which in RCM/ RCE’s opinion require a permit.
Safety Officers/ Auditors from Powai will inspect/ audit this aspect
when they visit the site.
Annexure – 1
Note :
* Some times more than one permit is required. While doing
grinding work in confined space requires ‘hot work permit’ as well
as ‘permit for entry into confined space’.
Special Instructions :
1. This permit must be available at the work site at all times.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
6. Permit renewal – for not more than 7 times including the issue date.
7. Permit shall be returned to issuer after completing the job.
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
____________________________________ ___________________ ________________ ________________________
Special Instructions :
1. This permit must be available at the work site at all times.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
6. Permit renewal – for not more than 7 times including the issue date.
7. Permit shall be returned to issuer after completing the job.
Additional Precautions required / Remarks, If any :
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
____________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)
TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)
LARSEN & TOUBRO LIMITED
E & C DIVISION Permit No.: -
GENERAL ELECTRICAL PERMIT(CSCL)
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Special Instructions :
1. This permit must be available in three copies two for initiator and one for issuer.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
6. Permit renewal – for not more than 7 times including the issue date.
7. Permit form shall be returned to issuer after completing the job.
8. (*) used only for energized equipment.
9. Use proper PPE while working with energized equipment / Non energized equipment
Additional Precautions required / Remarks, If any :
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
__________________ __________ ________ ____________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)
TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
______________________ _________ ________ _____________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)
LARSEN & TOUBRO LIMITED
E & C DIVISION Permit No.: -
HOT WORK PERMIT(CSCW)
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Special Instructions :
1. This permit must be available at the work site at all times.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
6. Permit renewal – for not more than 7 times including the issue date.
7. Permit shall be returned to issuer after completing the job.
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
____________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)
TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)
LARSEN & TOUBRO LIMITED
E & C DIVISION Permit No.: -
RADIOGRAPHY WORK PERMIT(CSCR)
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Location of work :________________________________________________________________________________
Source strength: ___________________________________ Curie: ____________________________________
Special Instructions :
1. This permit must be available at the work site at all times.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. The permit shall be submitted 4 hours before carrying out radiography to RCM/RE, L&T for his authorisation.
6. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
7. Permit renewal – for not more than 7 times including the issue date.
8. Permit shall be returned to issuer after completing the job.
Additional Precautions required / Remarks, If any :
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
____________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)
TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.
Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)
E & C Division SHE Manual
(A) Objective
(B) Procedure
(C) Administration
Annexure -1
The following rules are the minimum L&T standards applicable to all
visitors to this site and are supplemental to statutory laws &
regulations. If any doubt, please check with L & T - E & C Division
Resident Construction Manager / Engineer (RCM/E) or his staff.
1. Visitors shall enter into and work on this site at their own risk and
shall have own adequate insurance cover.
In order to set realistic goals for its process, the company should first
determine the major factors likely to cause loss of control. It should
determine where these factors are, their importance and their damage
causing potentials so as to evolve control measures, which could be in
the form of process/ work innovation etc.
WORKER
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Supervision
Programme Enforcement
Essential off the job safety involves employees, and is a term used by
employers to designate that part of their safety Programme directed
to the employees when they are not at work.
These will enable the proper utilisation of the space, unnecessary wastage
of material due to prolong storage, maintenance of better housekeeping
and hiring of costly equipment and skilled personnel for a minimum
period.
At the planning stage itself safety should be integrated in all the planned
activities. The material for construction, the machinery to be used and
the method of construction should all be evaluated with reference to the
site, the type of people to be engaged, the infrastructure available and
the environmental conditions and adequate in built safety measures and
work methods should be evolved.
Many accidents occur at the site due to tripping, slipping or falling over
materials and equipment which have been left lying around, and stepping
on nails which have been left projecting from timber. Good house
keeping is an important element of accident prevention. It should be
planned at the beginning of the job and carefully supervised until the final
clean-up while handing over the site to the client.
In general rubbish and scrap should not be left at the work site.
Gangways, working platforms and stairways should be clear of equipment
and materials, not in immediate use.
2. Work areas: loose materials, scrap, tools, etc shall not be allowed
to be lying in the working areas especially in the vicinity of ladders,
ramps stairs, etc. This is more important at heights where the loose
materials are liable to fall down.
Spills of oil and grease should be removed immediately.
An effective means like provision of receptacles should be provided
to store waste and scrap pieces.
4. Scrap yard : Wooden scrap yard should be well away from any
gas cutting or welding operations and 'No smoking' shall be strictly.
ensured. All other combustible wastes like cotton wooden boxes,
empty paint tins shall be disposed off safely within a reasonable
time.
7. The approach road from and to the work site shall never be
blocked by parking vehicles or stacking materials, etc. thus
blocking the movement in case of emergencies.
(a) All building materials are stored or stacked in a safe and orderly
manner to avoid obstruction of any passageway or place of work;
6. Civil work
6.1 Blasting
6.1.3 Transportation:
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body truck, a fire & waterproof tarpaulin shall be used to cover the
explosives.
6.1.4 Storage
• While taking explosives for actual usage, it shall not be placed near
sources of heat or water.
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• Replace the cover of the case after the required quantity of explosive
is taken out.
• Only fuse and nothing else shall be inserted in the open end of the
blasting cap.
• No. holes should be loaded except those that are to be fired in the
next round of blasting. Holes loaded during one shift should be fired
on the same shift.
• To avoid misfires, the detonator should be completely inserted length
wise in the cartridge, fastened in such a manner that it cannot be
pulled out accidentally.
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• Blasting should be carried out only during lean hours - say during
lunch time, night hours, etc.
6.1.7 Tamping
• Only wooden tamping tool should be used; if metallic parts are used,
they should be of non-sparking type. Primer should never be tamped.
A standard warning signal and an all clear signal should be used before &
after firing and inspection. All personnel working in the area and nearby
area should be made aware of this established warning procedures.
At the same time competent persons equipped with red flags should be
posted at all possible approaches to the blasting area to stop traffic and
by passers from entering the danger zone.
6.1.8 Firing
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5 - 25 100
25 - 50 150
50 - 100 220
100 - 250 350
250 - 500 450
500 - 1000 650
1000 - 2500 1000
2500 - 5000 1500
5000 - 10000 2200
10000 - 25000 3500
25000 - 50000 5000
50000 - 100000 7000
1 - 10 5
10 - 30 10
30 - 60 15
60 - 250 30
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6.1.9 Misfires:
There is no absolute safe method for handling misfires. But misfires can
be prevented,
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Construction Blasting Inspection
SSO: _________________________
Yes No NA
6.2 Excavation:
Underground Utilities
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Store and retain excavated material at least 2-ft. (61 m) from the
edge of the excavation to prevent excessive loading on the face of
the excavation. Remove boulders. Stumps or other materials that
may slide or roll into the excavation.
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Trench Excavation
Trenches more than 5-ft (1.5 m ) deep should be shore, laid back
to a stable slope, or provided with other equivalent protection
where employees may be exposed to moving ground or cave-ins
as per OSHA regulations. Trenches less that 5-ft (1.5 m) deep also
should be protected when studies show hazardous ground
movement may be expected. Bracing or shoring of trenches should
progress with the excavation.
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6.3 Piling :
There are certain hazards, which are common to all types of piling,
and the following precautions are necessary.
3. There should be a firm level base for the crane, or crane mats
provided;
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5. While the workers are working down a bore hole they must
wear a safety harness
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6. 4. 2. Ladders
Single Ladders
These are as single unit and intended to be used as such. The rungs are
generally round or horizontal in cross section.
Some ladders are provided with flat plates in which case they are called
stepladders. B.I.S.4435: 1967 specifies that the treads should be
horizontal, when the ladder is inclined at an angle 650 – 750 to horizontal.
Where ladders can not be placed directly then retaining hooks or devices
should be provided on top of the ladder.
Some of the dos and don’ts while using single ladder are given in
annexure-1.
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Working on Roof :
Roofs covered with asbestos sheets, roof light covering glass or perspex
can break under the weight of the person and working along perlins can
not be relied upon.
They should be atleast 38cm wide should have cross battens of at least
3.2cm thick and with a gap between them not more than 38cm.
For curved roofs, special ladders to suit the shape of the roof will have to
be designed.
The permit to work system given in the annexure (under the control of
respective person) can help to ensure that persons are not allowed to
work on roof without adhering to the above safety precautions. (a model
work permit is given in annexure-3).
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Falls from the side of the roof can be prevented by providing a strong
barrier at the edges of the roof.
6. 4. 3. Scaffoldings :
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! If a platform is used
as a footing only .......... 700 mm
! If a platform is used
for the deposit of material .......... 900 mm
! If a platform is used
for support of any platform .........1100 mm
! If a platform is used
for dressing stone or bricks .........1300 mm
! If a platform is used
for purposes stated in (3) & (4) above
..........1500 mm
! Extended at least 60 mm beyond the end of the support.
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The railings should consist of a top rail at a height not less than 90 cm
(max. 120 cm) above the platform and an intermediate rail halfway
between the top rail and the platform. The railings should be strong
enough to withstand a load of 90 kg applied in any direction on the top of
the rail.
6. 4. 4 Safety Belts
There are many situations where it may not be practicable to provide all
the normal measures to protect persons falling from heights. In such
cases, the persons should wear safety belts secured suitably through a
line to a proper anchorage.
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There are four common types of safety belts namely, Pole safety belt,
General purpose safety belt, General purpose safety belt with remote
anchorage and Harness (Man hoisting) type safety belt.
The material of the safety belt which should be chosen (leather and
webbing of natural and man-made fibers) according to the job
requirements.
Steel cables are not suitable for use as lifeline in case where a free fall is
possible, unless shock absorber is provided. The belts should be
maintained properly with periodic inspections.
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Annexure 1 (Ladders)
c) Ladder should be placed against a firm support for the stiles to rest on
it securely. One ladder should be fixed firmly either through lashing or
hooks at the top.
d) The slope of the ladder to wall / support should not be more than 75°
to the floor (i.e. 1 foot gap at the base to wall and 4 feet from the top
resting place to the ground.
e) Non slipping devices should be put to the bottom ends of ladder when
sued on slippery flooring.
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E & C Division
Safety at Working at Height Check-List
Name of Job site: -
SI. Description Observation Remarks
No. Yes/No
1. All the workers have been explained safe
work method?
2. An established communication system have
been established and explained to the
workers.
3 Adequate illumination has been ensured
4 Work area inspected prior to start the work
5. Area below the work place
barricaded,especially below hot work
6. Workers provided with bags/box to carry
bolts, nuts and hand tools.
7. Arrangement for fastening hand tools made.
8. All work platforms ensured to be of
adequate strength and ergonomically
suitable
9. Fabricated makeshift arrangements are
checked for quality and type of material
welding, anchoring etc.
10. Work at more than one elevation at the
same segment is restricted.
ACCESS / EGRESS
1. Walkways provided with handrail, mid-rail &
toe guard?
2. All checkered plates, gratings properly
welded / bolted?
3. Are ladders inspected and whether they are
maintained in good condition?
4. Are ladder spliced?
5. Are ladders properly secured to prevent
slipping, sliding or falling?
6. Do side-rails extend 36” above top landing?
7. Are built up ladders constructed of sound
materials?
8. Are rungs and cleats not over 12” on
center?
9. Metal ladders not used around electrical
hazards.
10. Proper maintenance and storage
11. Ladders placed at right slop
12. Ladders, staircases welded / bolted
properly.
13. Any obstruction in the stairs
14. Are landing provided with handrails, knee
rails, toe boards etc.
15. Whether ramp is provided with proper slope
16. Proper hand rail/ guards provided in ramps.
House – Keeping
1. Walk ways,aisles & all overhead
workplaces cleared of loose material
2. Flammable material,if any, are cleared
3. All deshuttering material are removed
after deshuttering is done
4. Platforms and walkways free from
oil/grease or other slippery material
5. Collected scrap are brought down or
lowered down and not dropped from
height
PPE and Safety Devices
1 Use of safety helmets,safety belts
ensured for all workers
2. Anchoring points provided at all places
of work
3. Common life line provided where ever
linear movement at height is required
4. Safety nets are in use wherever
required
5. Proper fall arrest system is deployed
at critical work places
6. Crawler boards/Safety system for
work on fragile roof are used
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6.6.2 Housekeeping :
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6.6.3 Machinery :
6.6.4 Operator :
6.6.6 Lighting :
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ANNEXURE 1
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Narrow strips thicker than the auxiliary fence-work support may enter the guard and strike the
baffle.Carefully raise the guard only enough to clear the workpiece. Use the push block to complete the cut.
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A clear plastic shield has been formed into a guard for this band saw.
Note the difference between a hold down (left) and a push block (right). The push block has a piece of wood
acting as a Positive stop against the end of the workpiece; the hold down is flat on the bottom, Both are used to
keep the operator's thumbs and fingers away from the cutter head.
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Introduction
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Ring test :
When unpacking abrasive disks and wheels, inspect them for
damage from shipment and perform the "ring' test. This test can
be used for both light and heavy disks or wheels that are dry and
free of foreign material. To conduct the ring test, suspend a light
wheel from its hole on a small pin or the finger, and place a
heavy one vertically on a hard floor. Then gently tap the wheel
or disk with a light tool, such as a wooden screwdriver's handle.
A mallet may be used for heavy wheels or disks. Make the tap at
a point 45 degrees from the vertical center line and about 1 or 2
in. (2.5 or 5 cm) from the periphery. A wheel or disk in good
condition will give a clear, metallic ring when tapped. Wheels
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and disks of various grades and sizes have different pitches. (ring
test to be done on receipt by the user.)
Visual Inspection on breakage, expiry dates designed rpm & wear
& tear of the wheel etc.
Daily inspection of grinding machines should include the points
shown in Figure.
Thoroughly investigate grinding wheel and disk failures,
preferably with the manufacturer's representative. This type of
investigation, along with immediate corrective action, greatly
reduces the possibility of recurrent failures.
The length of time abrasive disks and wheels may be stored and
still be safe to use should be in accordance with manufacturers'
recommendations. Give the ring test to disks and wheels taken
out of long storage. Follow this by a check for recommended
speed, and a speed test on the machine on which it will be
mounted. Check the speed of all grinding wheels against the
spindle speed of the machine-some are designed only for low-
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speed use. The grinding wheel must be rated at the same RPM
as the machine or more than the machine rpm. If it is not, the
wheel may explode and throw particles into the work area
causing serious at times fatal injuries.
Mounting wheels :
Key, screw, shrink, or press the inner or driving flange onto the
spindle. The bearing surface of the flange should run true with
the spindle. The outer flange's bore should easily slide onto the
spindle. (hand tightening , blotter paper)
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GRINDER CHECKLIST
TYPE _____________ RPM ________
Item OK NOT OK
INSPECTED BY _____________
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Because work has become wedged between the work rest and
the wheel, many bench and floor-stand grinder wheels have
broken, thus causing serious injury. The work rest should be
substantially constructed and securely clamped not more than
1/8 in. (3.2 mm) from the wheel. Check the work rest's
position frequently. The work rest's height must be on the
horizontal centreline of the machine's spindle.
Never adjust the work rest while the wheel is in motion. The
work rest might slip and strike and break the wheel, or the
operator might catch a finger between the wheel and the work
rest. To prevent work from adding twisting and bending stress
to the wheel, operators should use guides to hold the work in
position when slot grinding or performing similar operations.
Abrasive wheels that are not true or not in balance will produce
poor work. They can damage the machine and injure the
operator. Keeping the wheels in good condition eliminates
these possibilities, decreases wheel wastage, and lengthens the
wheel's life.
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6.7.11 Grindstones:
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After the stone has been centred, fill the central space about the
arbor with lead or cement. Use double thickness of leather or
rubber gaskets, rather than wood washers, wherever possible. If
wood washers are used between the flanges and the stone, the
washers should be '/2 to 1 in. (1.3 to 2.5 cm) thick and the
flanges should be clamped in place by heavy nuts.
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6.7.13 Mounting :
6.7.14 Safeguards :
Wire brush wheels or, more commonly, scratch wheels are used
to remove burrs, scale, sand, and other materials. These wheels
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Grinding Wheel
Grinding Wheel
Undercut
necessary Wheel Blotter
for firm fit
Flange Recessed
Wheel
Spindle Wheel Spindle
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The sills for shoring should be sound, rigid and capable of carrying
the maximum intended load. All baseplates, shore heads,
extension devices, or adjustment screws should be in firm contact
with the footing sill and the form. Prohibit eccentric loads on shore
heads and similar parts, unless these parts have been specifically
designed for such loading.
When single post shores are used one on top of another (tiered),
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Supply employees with eye and or face protection when nailing into
concrete. Require employees to wear this personal protective equipment.
Provide reshoring to safety support slabs and beams after stripping. Also
provide reshoring when slabs and beams are subjected to superimposed
loads due to construction. When temporary storage of reinforcing rods,
material, or equipment on top of formwork is needed, strengthen these
areas to meet the intended loads.
Adequately reinforce steel for walls, piers, columns, and similar vertical
structures to prevent overturning or collapse. Do not load metal tubular
frames used for shoring beyond the safe working load recommended by
the manufacturer. Keep all locking devices on metal tubular frames and
braces in good working order. Coupling pins should align the frame or
panel legs. Pivoted cross braces should have their center pivot in place.
All components should be in a condition similar to when originally
manufactured.
Fasten devices for attaching the outside lateral bracing to the legs of the
metal tubular shoring frames. When using tube and coupler shoring, use
coupler (clamps) made of drop-forged steel, malleable iron, or structural
grade aluminum. Do not use gray cast iron. Do not use couplers
(clamps) if they are deformed, or broken or have defective or missing
threads on bolts, or other defects.
When checking the erected shoring frames with the shoring layout, the
spacing between towels and cross brace spacing should not exceed that
shown on the layout. On metal tubular frame shoring, all locking devices
should be closed. On tube and coupler shoring, check all interlocking of
tubular members and tightness of coupling.
Guard all floor and roof holes, skylights, and openings into which persons
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Guard every stairway and ladderway floor opening on all exposed sides
except the entrance opening. Install a securely anchored standard railing
with intermediate rail and toe-board.
Guard wall openings from which there is a drop of more than 4-ft (1.2 m)
and the bottom of the opening is less than 3-ft (0.91 m) above the
working surface, with a top rail, top rail and intermediate rail, or standard
guardrail. Provide a toeboard where the bottom of the wall opening,
regardless of width, is less than 4-in. (10 cm) above the working surface.
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7. Mechanical works:
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• Frozen tissues are painless and appear waxy and yellow. They
will become swollen and painful and prone to infection when
thawed. Do not re-warm rapidly. Thawing may require 15 to
60 minutes. For white people, thawing should continue until
the pale blue tint of the skin turns pink or red. For black
people, assess frostbite by the swelling and blistering of the
skin. Reduction of swelling indicates alleviation of frostbite.
Morphine or tranquillisers may be required to control pain
during thawing and should be administered under professional
medical supervision.
• If the frozen part of the body thaws before the doctor arrives,
cover the area with dry, sterile dressings and a large, bulky
protective covering.
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7.1.1 Winch :
The following are some of the guidelines given for the safe
operation of the winches:
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7.1.2 Reeving :
The governing factor usually is the safe working load of the blocks,
rather than of the falls (rope).
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2. Friction loss (10% for each sheave) = 40% or 800 lb (363 kg).
2,000 + 800 = 2,800 lb (1,270 kg), which divided by 4 (the
number of parts at the movable block) = 700 lb (3 1 8 kg).
3. Applying the safety factor of 10 (10 x 700) gives 7,000 lb
(3,200 kg), the required breaking strength of the rope.
4. New Manila rope of 7/8 in. (22 cm) has a breaking strength of
7,700 lb (3,500 kg) and, therefore, is the proper size for the
load. Synthetic fibres would have greater tensile strength.
The safe work load limit for two double blocks made for rope Of
7/8- in. (22-cm) diameter is 2,000 lb (900 kg)-the equivalent of
the total load in the example.
Attach the rope to the block with a thimble and a proper eye splice.
A mousing of yarn or small rope should be placed on the upper
hook of a set of falls as a precaution against its accidental
detachment.
When blocks and falls are used to lift heavy materials or to keep
heavy loads in suspension, as on heavy-duty scaffolds, wire rope is
more serviceable than fibre rope.
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7.1.3 Rigging:
There are various methods of hitching the load to the hook through
choker hitch, basket hitch etc. Some of the types of hitching /
slinging are given below: -
Watch for
broken wires in
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A wire rope which has been A wire rope which has been
kinked. A kink is caused by subjected to repeated bending
pulling down a loop in a slack over sheaves under normal
line during improper handling, loads. This results in “fatigue”
installation, or operation. Note breaks in individual wires-these
the distortion of the strands breaks are square and usually in
and individual wires. Early rope the crown of strands
failure will undoubtedly occur
at this point.
The fiber, wire ropes and chain slings attachments are dealt under
appropriate headings.
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Method of Attachment:
All hooks and rings used as sling connections should develop the full rated
capacity of the sling.
Sockets and compression fittings, when properly attached with wire rope
sling should develop 100% of the rated strength of the wire rope. Swaged
sleeve sling endings should develop 92 to 95% of the wire rope’s strength.
Compression fittings and swaged sleeve fittings are available from the
wire rope manufacturers.
Hand tucked splices develop about 90% of the rope’s strength in ropes
having diameter less than ½” and 80% for larger diameters.
The recommended load rating for a sling assembly is usually based on 1/5
the calculated strength of the assembly.
As a general rule, hooks and rings, oblong links, pear shaped links,
coupling links and other attachments should be made of the same, or
equivalent, heat treatable alloy steel as the chain itself. In most cases the
attachments are provided by the manufacturers themselves.
When rigging irregular shaped loads or heavy loads proper rigging should
be made. Some of the special rigging methods are shown below: -
Identification
tag
Safety lock
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This hitch
Single Double compresses the
Wrap Basket Hitch load and prevents
it from slipping Pair of Double
out of the slings. Wrap Basket
“Double” choker
Use to turn loads
Not recommended
Recommended
Right
Wrong
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Load held on
Load held on Two part of
one part of rope rope
Packers to
prevent
chafe
Sling with two separate legs Endless Sling with Two legs
SWL= 1.25 x SWL of rope and Choke Hitch
SWL= 1.60 x SWL of rope
Packers to
prevent chafe
Packers to
prevent
chafe
Endless Sling with Four Legs Sling with Four Separate Legs
SWL= 1.60 x SWL of rope SWL= 2.00 x SWL of rope
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Sling Calculation: -
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Double, Triple, quad chain Out - of - balance load by a double sling with
sling to handle loads of chain leg adjusted (Two short chains with
virtually any size or shape. grab hooks attached to the master links.)
Wear
Surfa
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The format for keeping the record of annealing of loose gear is given
in annexe 5.
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2. Centre the crane over the load before starting the hoist to avoid
swinging the load as the 1ift is started. Loads should not be
swung by the crane to reach areas not under the crane ( Figure
below )
4. Never lower the block below the point where less than two full
wraps of rope remain on the hoisting drum. Should all the rope
be unwound from the drum, be sure it is rewound in the correct
direction and seated properly in the drum grooves, otherwise
the rope will be damaged and the hoist limit switch will not
operate to stop the hoist in the high position.
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6. Do not make lifts beyond the rated load capacity of the crane,
sling chains, rope slings, etc.
8. Make certain that before moving the load, load slings, load
chains, or other load lifting devices are fully seated in the
saddle of the hook.
10. On all capacity or near capacity loads, the hoist brakes should
be tested by returning the master switch or push button to the
OFF position after raising the load a few inches off the floor. If
the hoist brakes do not hold, set the load on the floor and do
not operate the crane. Report the defect immediately to the
supervisor.
11. Check to be sure that the load is lifted high enough to clear all
obstructions and personnel when moving bridge or trolley.
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14. Do not lift loads with any sling hooks hanging loose. (If all sling
hooks are not needed, they should be properly stored or a
different sling should be used.)
15. All slings or cables should be removed from the crane hooks
when not in use. (Dangling cables or hooks hung in sling rings
can inadvertently snag other objects when the crane is moving.)
16. Crane operators should not use limit switches to stop the, hoist
under normal operating conditions. (These are emergency
devices and are not to be used as operating controls)
18. Upper limit switches (and lower limit switches, when provided)
should be tested in stopping the hoist at the beginning of each
shift, or as frequently as otherwise directed.
21. If the electric power goes off, place your controllers in the OFF
position and keep them there until power is again available.
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25. When two or more cranes are used in making one lift, it is very
important that the crane operators take signals from only one
designated person.
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Derricks:
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Frame Derrick
Guy Derrick
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CRANES:
Some of the common types of crane in use at the site are given below:
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The Do’s and Don’ts of operation have been given under Ropes and Rigging.
• Operator’s skill
• condition of the ground
• Boom length
• Radius of rotation while lifting the load inclination of boom to the
vertical
• out rigger blocked/free
The Safe working load is generally tabulated in the Load chart of the
crane. Sometimes cranes are derated due to the defects in welding,
bend in angle, Bracing etc; and Condition of clutch brake, etc.
The load is the total load, hung from the rope sheaves of the boom
including weight of hook block, ropes/slings, etc.
6. Tag lines should be used while hoisting heavy and bulky materials.
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7. The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by Maintenance personnel to ensure
the crane's safe operation.
9. The boom or any part of the crane should not come near any live
electric line/service line.
11. Proper quality of packing should be used and the outrigger should
rest tightly on the packing.
13. The operator should be able to see the hook and load throughout the
hoisting period.
14. During storm, the hook block should be anchored firmly and swing
lock be released.
15. When an extended boom is used on the crane, the operator must use
extreme care in lowering load to the ground. An extended boom
never should be lowered to one side of the chassis for the stability of
the crane is usually reduced in that position and the crane will get
over turned.
16. The crane has to be travelled on a heavy timber mat whenever there
is instability of soil.
17. The use of any make shift methods to increase the capacity of crane
such as timbers, with blocking, or adding counter-weight, should not
be permitted.
18. Before leaving the crane at the end of the workday, the crane
operator should remove the load from the hook and raise the hook
block to maximum height.
19. The crane operator should keep the deck clean of any oil, mud and -
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grease.
20. Operator should always keep the windshield clear, in order to prevent
accident due to this.
21. Ensure atleast two full turns of rope be always on the rope drum.
After a boom extension, the hooks shall be lowered to the required
lowest point to ensure that atleast two turns of rope remain on the
drum and to the highest point to check that the drum capacity will not
be exceeded.
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Mobile Cranes:
5. The Safe working load is generally tabulated in the Load chart of the
crane.Sometimes cranes are derated due to the defects in welding,
bend in angle, Bracing etc; and Condition of clutch brake, etc.
6. The load is the total load. hung from the rope sheaves of the boom
including weight of hook block, ropes/slings, etc.
8. The Crane Operator shall respond to signals only from the appointed
signaller but shall obey stop signal at any time no matter who gives
it.
9. Tag lines should be used while hoisting heavy and bulky materials.
10. The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by a Maintenance person to ensure the
crane's safe operation.
11. The load being lifted should not touch the boom.
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12. The boom or any part of the crane should not come near any live
electric service line.
14. Proper quality of packing should be used and the outrigger should
rest tightly on the packing.
16. When travelling up a gradient, the load shall be kept in front of the
crane and when travelling down a gradient, the crane should travel in
the reverse and on reaching level ground it should travel in the
normal way otherwise, constant watch on the radius should be
maintained while travelling on uneven surfaces.
17. The mobile crane shall be fitted with suitable horn, Headlights, Side
Lamps, rear and stop lights and flashing direction indicator.
18. Cranes with cantilever type jib, when travelling without load, the jib
should be lowered to a horizontal position.
19. The pneumatic tyres shall be maintained at the correct pressure at all
times.
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Signature of RCM :
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Structural Erection:
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7. Care should be taken while lifting loads. Proper tag line must
be used for guiding while lifting loads.
9. Loose bolt, nuts and tools must be kept in boxes and not on
structures. Boxes must have proper anchorage.
11. Providing padding over sharp edges should protect ropes and
slings.
15. All safety appliances like safety helmet, gloves, safety belts
must be used in erection site. All persons working at height and
standing on structural members must wear safety belts
equipped with suitable lifeline. Lifeline must be tied to any
independent strong members.
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18. A lot of precautions are to be taken for erecting roof girders and
roof trusses as they are usually slender, very long and unstable
by themselves. The trusses, which have a bracing system,
should be erected first and held by separate cranes and only
after bracing are fixed, the crane should be released. For all
other spans, only purling and horizontal runners need to be
fixed before release of cranes. Roof truss should never be
erected along with monitor roof truss. Monitor roof should be
erected separately.
20. C.G.1 sheet should be kept tied on the top. The required
number of CGI sheets only should be lifted and unbolted.
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This chapter deals with different types of slings, their use, care and
maintenance.
Nylon rope:
• Nylon rope has over two and a half times the breaking strength
of Manila rope and about four times its working elasticity. It is,
therefore, well suited to shock loading, such as is required for
restraint lines.
• Its resistance to abrasion is remarkably high in comparison to
other ropes.
• While nylon rope is wet or frozen, its breaking strength is
reduced by 10% to 15%.
• Nylon rope also is highly resistant to organisms that cause
mildew and rotting and to attack by marine borers in sea water.
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Polyester rope:
Polyolefin rope:
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Composite rope :
Working Load :
• Because the safety factor is not the same for all ropes and is
based upon static loading, caution has to be exercised while
using thumb rule. Also caution has exercised when using the
working load figures supplied by the manufacturer.
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• If possible, do not drag rope since this wears away the outer
fibres. If a rope picks up dirt and sand, abrasion within the
strands of the rope will rapidly wear it out.
• Handle twisted rope so it retains the amount of twist (called
balance) that the rope seeks when free and relaxed. If rotating
loads and improper coiling and uncoiling change the balance,
restore it by properly twisting the rope at either end. Severe
unbalance can cause permanent damage; localised over twisting
causes kinking or hocking. Kinking strains the rope and may
over stress the fibres. It may be difficult to detect a weak spot
made by a kink.
• To prevent a new rope from kinking while it is being un -coiled,
lay the rope coil on the floor with the bottom end down. Pull
the bottom end up through the coil, and unwind the rope
counter clockwise. If it uncoils in the other direction, turn the
coil of rope over, and pull the end out on the other side.
• Avoid sharp bends over an unyielding surface since this causes
extreme tension on the fibres. To make a rope fast, select an
object with a smooth round surface of sufficient diameter.
• If the object does have sharp corners, pad the corners.
• Thoroughly dry out rope that has become wet; otherwise, it will
quickly deteriorate. Do not allow wet rope to freeze. Hang up a
wet rope, or lay it in a loose coil in a dry place until thoroughly
dry. Rope deteriorates more rapidly if it is alternately wet and
dry than if it remains wet.
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• Wire rope is more widely used than fibre rope. Wire rope has greater
strength and durability under severe working conditions than does fibre
rope. The physical characteristics of wire rope do not change when
used in varying environments. Wire rope has controlled and
predictable stretch characteristics.
Construction
• Wire rope is composed of steel wires, strands, and core. The individual
wires are cold drawn to predetermined size and breaking loads according
to required grades. Grades include iron, tractor, mild plow steel, plow
steel, improved plow steel, and extra-improved plow steel. The wires
are then laid together in various geometrical arrangements according to
construction requirements for strands and classifications of wire rope (6
x 19, 6 x 37, etc.).
• The service for which the rope is to be used determines the size, the
number and arrangement of wires, the number of strands, the lay, and
the type of core In a wire rope.
Classifications:
• The most popular and most generally used constructions of wire rope are
six-strand ropes of these two classifications-the 6 x 19 and 6 x 37. The
6 x 19 classification contains a variety of constructions for wire rope,
ranging in number of wires per strand from 15 to 26. Typical
constructions are 6 x 19 Seale, 6 x 25 filler wire, and 6 x 19 Warrington.
• The 6 x 37 classification also covers a large number of designs and
constructions for wire rope with the number of wires per strand ranging
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• In ropes with large diameters, 2 in. (6.4 cm) and larger, practically all
wire rope is produced in the 6 x 37 or 6 x 61 class. Therefore, because
of the large number of possible rope constructions that are available,
exercise care to make the proper selection
Service Requirements:
• Since preformed wire rope does not unravel, it has advantages for
certain services, such as for slings to hoist heavy construction
equipment. Preformed wire rope is less likely, to set or kink; thus,
broken wires are less likely to protrude and create a hazard to workers.
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• The operating or design factors for rope used in hoisting are calculated
by dividing the nominal catalogue strength of the rope by the sum of the
maximum loads to be hoisted. It is normal practice to base this on static
loads. It is recommended that hoisting rope have at least the strength
of improved plow steel. For some applications, use extra-improved plow
steel, which is the greatest in strength, to provide an adequate design
factor and better service.
• The minimum design factors for rope used in hoisting depend upon the
type of service required and the state codes covering the particular
hoisting operation. Many of these codes describe exactly how the design
and operating factors should be figured. Therefore, it is prudent to
check what codes are in force before making a final determination or
selection of wire ropes to be used in hoisting. Also obtain the advice of a
reliable wire rope manufacturer.
Causes of Deterioration:
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Lubrication:
Chain Slings:
• The safety of a chain sling assembly depends on the material used, its
strength for the load handled, method of attaching chain to fittings, and
proper inspection and maintenance. Alloy steel is the standard material
for chain slings because of its resistance to corrosion and wear and high
tensile strength. Hooks and attachments are generally made of the
same material,
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• Synthetic web slings and metal mesh slings are also widely used in
industry. Synthetic web slings are useful for lifting loads that need their
surfaces protected; however, these slings are easily cut and have little
resistance to abrasion. As a result, these web slings require an initial
inspection, frequent on-the-job evaluation, and periodic formal
inspection by trained personnel.
Remove metal mesh slings from service if a broken weld or brazed joint is
discovered along the sling edge. Also watch for the following signs of wear.
Any one of these conditions or a combination of them, if ignored, could
eventually result in sling breakdown:
• bent links
• cracks in weld areas, in shoulders, or in any other section of link
• kinks and gouges
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When inspecting the hook, measure between the shank and the narrowest
point of the hook opening. Whenever the throat opening exceeds 15% of
the normal opening, replace the hook. Pay special attention to slings to
which hooks have been added; make sure the hooks are secure.
Safe Practices
The following safe practices for all slings are given as guidance:
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• Slings having suitable characteristics for the type of load, hitch, and
environment shall be selected in accordance with appropriate
specifications.
• The weight of a load shall be within the rated load capacity) of the sling.
• Slings shall not be shortened or lengthened by knotting or other
methods not approved by the sling manufacturers.
• Slings that appeared to be damaged shall not be used unless inspected
and accepted as usable.
• Sling shall be hitched in a manner providing control of the load.
• Sharp corners in contact with the sling should be padded with material of
sufficient strength to minimise damage to the sling.
• No portions of the human body should be kept from be the sling and the
load, and from between the sling a crane hook or hoist hook.
• Personnel should stand clear of the suspended load.
• Personnel shall not ride the sling.
• Shock loading should be avoided.
• Slings should not be pulled from under a load when load is resting on the
sling.
• Slings should be stored in a cool, dry, and dark place to prevent
environmental damage.
• Twisting and kinking the legs (branches) shall be avoided.
• A load applied to the hook should be centred in the base (bowl) of the
hook to prevent point loading on the on the hook.
• During lifting, with or without a load, personnel shall be alert for possible
snagging.
• In a basket hitch, the load should be balanced to prevent slippage.
When using a basket hitch, the sling's legs (branches) should contain or
support the load from the sides above the centre of gravity.
• Slings should be long enough so that the rated load (rated capacity) is
adequate when the angle of the legs (branches) is taken into
consideration.
• Slings should not be dragged on the floor or over an abrasive surface.
• In a choker hitch, slings shall be long enough so the choker fitting
chokes on the webbing and never on the other fitting.
• Nylon and polyester slings shall not be used at temperatures in excess of
194 F (90 C).
• When extensive exposure to sunlight or ultraviolet light is experienced
by nylon or polyester web slings, the sling manufacturer should be
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Sheaves:
• The condition and contour of sheave grooves Is important for the service
life of wire rope. Periodically check sheave grooves (Figure 10-4), and
do not let them wear to a smaller diameter than those shown for used
grooves in Table 10-G. If they become worn more than this, expect a
reduction in the rope's service life. Reconditioned sheave grooves
should conform to the tolerance, shown in Table 10-G, for new (or re
machined) grooves.
• On all new sheaves, the grooves should be made for the size of rope
specified. The bottom of the groove should have a 150-degree arc of
support, and the sides of the groove should be tangent to the ends of
the bottom arc. The depth of the groove should be one times the
nominal diameter of the rope. The radius of the arc should be one-half
the nominal rope diameter plus one-half the value.
• Check sheaves for proper alignment when they are installed. During
rope changes, check the sheaves for worn bearings, broken flanges,
proper groove size, smoothness, and contour. Recondition or replace
heavily worn or damaged sheaves.
• Sheave groove bearing pressures can become very hot depending upon
operating conditions and rope loading. High pressures can cause
excessive sheave wear and shorten the life of wire rope. It is necessary,
therefore, to consider this factor and to select proper sheave materials
and liners at the time of installation. Information on this subject may be
found in most wire rope manufacturers' handbooks.
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Average
Rope Recommended
Classification (times rope diameter) Minimum
6x7 72 42
6x19 45 30
6x37 27 18
8X19 31 21
Drums:
• Minimise crushing and excessive wear of wire rope using spirally grooved
drums with capacity for one layer rope. In any case, limit the number of
layers to three. Rope lifters at the flanges are recommended when two
or more layers are wound on drums. To distribute wear uniformly
crossover points, cut off one-and-a-quarter wraps every 6 months or
three or four times during the life of the rope. In no case should there be
fewer than two full wraps on a drum; three is preferred.
• In general, avoid reverse bending of wire rope (bending first in one
direction and then in the opposite) over sheaves or drums. This wears
out the rope faster.
• Correct fleet angle is important for even, efficient winding of wire rope.
The fleet angle is the included angle between the rope winding on the
drum and a line perpendicular to the drum shaft and running through
the head or lead sheave.
• To reduce any tendency for the rope to open-wind, do not let the fleet
angle exceed 1o30'. To assure the rope's starting back on the next
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layer, use a minimum angle of 0030’ for smooth drums and 2o for
grooved drums. Adhering to these 'fications helps achieve uniform
winding on smooth-faced drums and also increases the winding
efficiency of grooved drums. For smooth-faced drums, proper direction
of lay of rope for specified winding conditions further helps achieve
uniform winding.
• Installing a wire rope on a plain- or smooth-faced drum requires a great
deal of care. The starting position should be at the drum end so that
each turn of the rope winds tightly against the preceding turn. Maintain
close supervision during the entire installation process to make sure
that:
1. the rope is properly attached to the drum
2. appropriate tension on the rope is maintained as it is wound on the
drum
3. each turn is guided as close to the preceding turn as possible so that
there are no gaps between turns
4. there are at least two dead turns on the drum when the rope is, fully
unwound during normal operating cycles. Loose and uneven winding
on a plain- or smooth-faced drum, can, and usually does, create
excessive wear, crushing, and distortion of the rope. The results of
such abuse are lower operating performance and a loss in the rope's
effective strength. Also, on jobs that require moving and spotting a
load, the operator will encounter control difficulties because the rope
will pile up, pull into the pile, and fall from the pile to the drum
surface. The ensuing shock can break or otherwise damage the
rope.
Pulleys:
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Link tend to
close – up Bend
and
elongate
Stretched
Link
Twisted Wear
Link
Bend
Remaining Material
Cuts
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HOOKS:
Normal Defective –
Throat Open
Throat opening
more than 15% -
Hook should be
rejected
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SHACKLES:
Rope Fittings:
Fittings are important for safety because they develop from 75% to 100%
of the breaking strength of the rope. Manufacturers also specify fittings of
suitable size and design for ropes of different sizes.
The efficiency of mechanical sleeve splices varies from 90% to 95% when
IWRC-type wire rope is used.
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Socketing with zinc and a thermostate plastic resin will develop 100% of
the rope's breaking strength.
Since there is no ready way to detect flaws in the finished job, follow the
recommended procedure exactly.
Square knots and other types of knots have low and unpredictable
efficiencies-40% or less. Using them is likely to result in the failure of a
rope assembly and under certai conditions to result in serious accident.
For the latter inspection, the rope speed is generally less than 60 feet per
minute (fpm).
The supervisor checks specifically for wear of the crown wires, kinking, high
strands, corrosion, loose wires, nicking, and lubrication. Rope callipers and
micrometers are used to determine changes in the cross section of rope at
various locations.
The number of broken wires per lay is one of the principal bases for judging
the condition of a rope. If most of the broken wires in a lay are
concentrated in several strands, that section of the rope is weaker than it
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7.5 Hoists
Hoisting towers are usually made of tubular steel and are used on
construction sites. Base the design on a safety factor of at least
five. Erect the tower on a level and solid foundation, and have it
well guyed or fastened to the building.
Enclose the tower with heavy wire screening and equip it with a
fixed ladder extending the full height of the tower. Install standard
railings and toe-boards on runways connecting the tower to the
building.
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Signal Systems
Personnel Hoists
Any hoist used for carrying passengers should conform to the safety
requirement of BSI. Rack and pinion hoists can be used to carry
personnel or material but never both, according to strict
manufacturing specifications and safety rules. Include all safety
devices, including an over-speed governor, normal limit and final
limit switches and thoroughly inspect and maintain the hoist
regularly.
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Where multiple hoistways are used and one or more of the cars are
designed solely as a material car in accord with ANSI 10.5 personnel
cars are prohibited. Each personnel hoist should be independently
powered and operated. Never use Chicago booms on a hoist
structure.
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Use hoisting ropes not less than ½-in. (1.25 cm ) in diameter except
on such equipment as small winches, like those on gin poles. In any
case, they should provide a safety factor conforming to the
requirements of applicable elevator codes. Inspect ropes frequently
and keep them lubricated. Replace ropes when inspection discloses
that wear, breakage, or corrosion has reduced their strength below
the permitted safety limit.
Where clip fastenings are used, there shall be at least three clips,
with the U-side on the dead end of the rope. Ropes shall be
guarded at points where persons may come in contact with them
and where objects may strike or rub against them. Keep sheaves
aligned and bearings lubricated. In general, sheaves diameter
should be at least 20 times the rope’s diameter.
Hoisting Engines
Engines should have brakes that can stop and hold 150% of the
rated safe load. In addition, engines should have a pawl for holding
suspended loads.
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Powered Trucks:
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plant, the contractor and the plant's management should agree upon
the traffic flow. In that way, the areas in which the construction
equipment is to be operated will be known and isolated where
possible. The contractor’s key personnel and the plant's designated
personnel should receive drawings of these areas.
(1) to prevent the operator from being pinned between the truck
and a fixed object and
(2) to prevent the truck running up on the operator's heels.
Industrial trucks should not be used for any purpose other than the
one for which they were designed.
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Operators are responsible for the care of trucks and should never
leave a truck unattended, park in an aisle or doorway, idle engines
for too long, or ignore mechanical problems.
When driving, they should keep arms and legs inside the truck's
guard or operating station, keep passengers off the truck, and watch
out for pedestrians.
Operators should inspect their trucks before and after each shift.
Repairs, replacements, or other work should be performed only by
trained mechanics wearing proper protective equipment, particularly
when handling electrically powered trucks. Repairs or re-fuelling of
gasoline and liquefied petroleum trucks should be done as per
norms/instructions to avoid health hazards and burns and
explosions. Only authorised fuel and fuel tank equipment should be
used on these trucks.
Secure all equipment being towed not only with a regular hitch or
drawbar but also with a safety chain attached to the pulling unit. A
drawbar failure can result in a serious accident.
When towing a scraper from one job to another, the operator should
use a scraper bowl safety latch, or place a safety bolt in the beam to
give maximum clearance for road projections such as at crossings.
This precaution prevents the bowl from striking the ground or
pavement and injuring persons or damaging equipment.
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Clearing work:
Special hazards:
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Supply safety belts for all passengers who ride in the cabin with the
driver.
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Do not permit debris, oil, grease, oily rags, and waste to accumulate
on equipment.
Flammable liquid:
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Workers should not use solvents with flash points below 100 F (37.8
C) for cleaning equipment or parts.
When gasoline and other highly flammable fluids are used, transfer
them by approved pumps or store them in approved safety cans. Do
not store gasoline, fuel oil, and other flammable or combustible
liquids on equipment except in fuel tanks or approved safety cans.
Repairs:
Post suitable signs, and do not remove them until repairs have been
completed.
For repairs on equipment made away from the source of power, such
as conveyors and cable ways, use chains, blocking, or similar
devices. Such precautions will prevent injury in case the equipment
is accidentally started.
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Operators should realise that lift trucks are generally steered by the
rear wheels, handle more easily when loaded, are used in reverse as
often as forward, and are often steered with only one hand. Drivers
must be shown how to handle various types of loads, to drive on
different gradients, to load and unload the truck properly, and to
stack pallets safely.
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Some useful tips for drivers for safe operation of the fork lift
truck:
Pre-Use Inspections:
- Always inspect the forklift before you start work. ( mast for
broken weld, proper lubrication of roller tracks and chain, forks
properly placed/not cracked, hydraulic fluid level and leakage)
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Safety Tips:
Always travel with load tilted slightly back, keep load at proper
height. Drive slow. If you can't see, drive in reverse.
Safe Steering: Drive slowly, slow for turns; stay wide when turning
into aisles.
Slippery floors - Slow speed, brake carefully, and avoid tight turns.
Heavy traffic areas - Set loads carefully, maintain safe speed, and
use horn to alert others.
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! Make sure that the working platform is secure and has no tripping
hazards such as tools, wire, timber or bricks. Surfaces soon become
slippery and should be treated immediately by cleaning, gritting or
applying industrial salt or sand.
! Check that access ladders guard-rails and toe boards are firmly fixed in
position.
! Wear a safety helmet at all times - if you are struck on the head and
fall into water you are at special risk.
! Check that lifebuoys fitted with lifelines are ready to hand for
immediate use.
! Make sure that there is a safety boat and that it is manned while you
are working above water - if over tidal water or a fast-flowing river, it
must have a motor with a self-starting device Ensure that you know the
routine for raising the alarm and for rescue drill.
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If you are one of the workers who work in confined spaces each year, you
know your job is dangerous.
Serious injury or death in a confined space can be result of:
" Asphyxiation
" Engulfment
" Electric shock
" Fall & heat stress
NOISH defines a confined space as
Class A spaces are those that present situation which are immediately
dangerous to lift or health. These include spaces that are either deficient in
oxygen or certain explosive, flammable or toxic atmospheres.
Class B spaces do not present an immediate threat to life or health:
however, they have the potential for causing injury or illness if protective
measures are not used.
Class C spaces are those where any hazards posed are so insignificant
that no special work practices or procedures are required.
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A. Atmospheric Hazards
# Oxygen deficiency atmospheres.
# Oxygen enriched atmospheres.
# Flammable atmospheres
# “Toxic” or irritating atmospheres.
B. Physical Hazards:
# Unexpected movement of machinery.
# Electrocution by electrically energized conductors.
# Fluids: liquids, powders and gases.
# Heat stress, Thermal condition: hot or cold.
# Engulfment by finely divided material or liquid.
# Ionizing and non-ionizing radiation.
# Contact with corrosive substances.
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Permit Authorisation:
# The entry supervisor fills up the confine space entry work permit.
# After verifying that acceptable entry conditions exist, the entry
supervisor signs and dates the permit.
# ONLY THEN workers are allowed to enter the permit space.
! The air in the vessel must be tested for oxygen and for flammable and
toxic gases before entry
! Lifelines and safety harness must be used by all the persons entering in
the confined spaces.
! A person must also be stationed outside the vessel in a position to
handle the lifeline and to summon assistance in case of an emergency.
! Self-contained breathing apparatus must be kept ready for emergency.
! All the inlet of the vessel that could injure the entrant if operated
unexpectedly must be blinded or locked in the“Safe” position.
# Minimum general ventilation rate of 2000 cubic feet per minute per
welder be maintained in confined spaces.
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# If local exhaust is used, the capture velocity at the point of work must
be at least 100 feet per minute.
# Local exhaust or air-supplied respirators must be provided if welding,
cutting or heating is performed on beryllium -, lead -, cadmium - or
mercury -coated base metals.
# Welding machines and compressed gas cylinders must be kept outside
the confined spaces.
# When work stops for a prolonged period of time, electrodes must be
removed from their holders and gas flow to torches must be shut off
from outside the space.
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OR
# Permit flammable gases and vapors to ignite over a much wider range
of concentrations than is possible in ordinary air.
# Alters the burning characteristics of many materials, making them
both easier to ignite and faster burning once ignited.
Sources
Critical Jobs 10
E & C Division SHE Manual
Introduction:
The purpose of welding is to join metal parts. All welding process requires
heat and sometimes other substances to produce the weld. Because high
heat is used to make the weld, a number of by-products results from the
process, including fumes and gases that can be a serious health hazard to
workers. Safety hazards are also associated with welding, such as the
potential for fire or explosion and injuries form arc radiation, electrical
shock, or material handling.
Definitions used in this chapter are those of the American Welding
Society. “Welder” and “Welder Operator” refer to the individual only. The
machine performing the welding operation is referred to as the “Welding
machine”. Equipment supplying current for electric welding is called either
a “Welding generator” or a “Welding transformer”.
Hazards:
1. Health Hazards:
• Asphyxiation
The major toxic gases associated with welding are classified as
primary pulmonary and nonpulmonary.
(d) Asbestos
If welding or cutting involves asbestos, the regulations of the
agency having authority must be consulted before beginning the
job. Asbestos can produce fibrosis and lung and other cancers.
2. Safety Hazards
hot slag from reaching such material and starting fires. If the
work itself cannot be moved, the exposed combustible material
should, if possible, be moved a safe distance away. Otherwise, it
should be covered with sheet metal. Spray booths and ducts
should be cleaned to remove combustible deposits. Before
welding or cutting is started, wood floors should be swept clean
and, preferably, covered with metal or other non-combustible
material where sparks or hot metal may fall. In some cases, it is
advisable to wet down the floor, though the wet floor increases
the shock hazard to electric (arc and resistance) welders and
necessitates special protection for them.
Hazardous Locations
The accepted method for preparing tanks and drums for welding is:
6. Remove the drums from the steaming rack, and fill drum part way
with caustic soda or soda ash solution. The drums for at least 5
minutes. Light hammering with a wood mallet will help to loosen
scale.
7. Thoroughly flush the drums for at least 5 minutes boiling water. A
water spray nozzle placed 6 to 8 in to 20 cm) inside the drum can be
used. Drums should placed so that water can drain out the
8. Wash down the outside of the drum with a hose stream of hot water.
9. Dry the drum thoroughly by circulating warm air throughout the
inside.
10.Thoroughly inspect the interior of the drum, using a light that is
listed for hazardous locations, and a small mirror. If it is not clean,
repeat the cleaning process.
11. Test the container for the presence of flammable vapours with a
combustible gas indicator. Test for toxic contaminants and for oxygen
sufficiency or enrichment if personnel are to enter.
12. Make similar tests just before welding repair operations are
performed. If operations extend over an appreciable period of time,
make repeated tests.
Ventilation
• Space of more than 10,000 ft3 (284 m-3) per welder is provided
• Ceiling height is more than 16 ft (5 m)
• Welding is not done in a confined space
• Welding space refers to a building or an enclosed room in a building,
not a welding booth or screened area that is used to provide
protection from welding radiation; nor does the welding space
contain partitions, balconies, or other structural barriers that
obstruct cross-ventilation m materials covered above are not
present as deliberate constituents.
velocity of 100 ft per min (30 m per min), and be maintained for a
distance 'Of approximately 2'ft (0.6 m) directly above the work area.
Precautions must be taken to ensure that contaminants are not
dispersed to other work areas.
6. Do not use cylinders for rollers, supports, or any purpose other than to
contain gas.
11. Always consider cylinders as full and handle them with corresponding
care. Accidents have resulted when containers under partial pressure
were thought to be empty.
12. The fusible safety plugs on acetylene cylinders melt at about the
boiling point of water. If an outlet valve becomes clogged with ice or
frozen, it should be thawed with warm (not boiling) water, applied
only to the valve. A flame should never be used.
13. Cylinders together with their valves and other fittings and other
fittings and the identification colours under these rules shall always
be maintained in good condition.
14. No oil similar lubricant shall be used on any valves or other fittings of
any cylinder.
15. Every cylinder containing compressed gas shall have valve securely
closed so as to prevent leakage.
16. If a leak in the valve can not be rectified by lightening the gland nut
or the spindle, the cylinder shall be removed to an open space where
it is least dangerous to life and properly and the filler shall be
informed.
Rule 9(2) of gas cylinder rules, 1981 prescribes 4 warning in the following
terms are attached to every cylinder containing permanent or liquefiable
gas, namely:
“WARNING”
Gas Cylinder Rules, 1981
COLOUR CODING:
The cylinders should be painted as per the Indian Standards for easy
identification. To prevent inter change of fittings, the valve out lines are
screwed left and right respectively.
5. Store acetylene and liquefied fuel gas cylinders with the valve end up.
12. Never permit cylinder to have contact with direct flame or electric
arc.
13. For storage of gas cylinders flammable storage rooms for cylinders
containing flammable gases should be well ventilated to prevent the
accumulation of explosive concentrations of gas.
14. Never allow cylinders to come into contact with electrical apparatus
or live wires, since arcing may be set up which will heat or damage
the cylinders.
15. Never strike an arc or tap an electrode on a gas cylinder whether full
or empty.
17. Never transport cylinders with the regulators and hose attached
unless a proper trolley or carrier is used. When transporting by a
trolley the cylinder valve must be shut before the cylinder is moved
from place to place.
5. There are two types of blowpipes in common use i.e. low pressure and
high pressure. Remember, a low pressure blow pipe may be used on a
high pressure system, but under no circumstance, can a high pressure
blow pipe be used on a low pressure system.
6. Inspect rubber hose periodically to see that it is free from cuts, cracks,
burns and worn places and arranges it so that it can not be cut by
contact with sharp edges or corners, falling metal, sparks or the blow
pipe flame.
7. Use red hoses for acetylene and to other fuel gases and black for
oxygen and be careful to see that they are never inter changed.
8. Use hoses of equal length and do not coil any surplus hose around
regulators or cylinders.
10. Cylinders should not be used to support the work, nor should the
blow pipe flame be allowed to come in contact with the cylinders. The
blow pipe when alight should not be hung on the cylinder or on the
regulator.
11. To blow out dust or dirt that otherwise might enter the regulator,
“crack” the discharge valve on the cylinder by opening it slightly for
an instant and the close it. On a fuel gas cylinder, first see that no
open flame or other source of ignition is near; otherwise, the gas
may ignite at the valve.
12. Connect the regulator to the outlet valve on the cylinder. Be sure the
regulator inlet threads match the cylinder valve outlet threads. Never
connect an oxygen regulator to a cylinder containing fuel gas, or vice
versa. Don’t force connections which do not fit. Be sure that the
connections between the regulars and cylinder valves are gas-light.
13. Release the pressure adjusting screw on the regulator to its limit –
turn it counter - clockwise until it is loose.
14. Open the cylinder valve slightly to let the hand on the high pressure
gauges move up slowly. On an oxygen cylinder gradually open the
cylinder valve to its full limit, but
5. Ensure that all connections are clean and tight, that they are correctly
made, that the correct types and sizes of cables, earthing clamps,
electrode holders, cable connectors are being used.
Wear leather apron to protect his body and clothing from the heat of
the work, to prevent burns which can be caused by small globules of
metal falling on his thigh and legs, and in gas shielded ultra-violet
radiation and ozone on clothing.
(B) Gloves
To protect the hands against heat, spatter and radiation, gloves must
be worn, and these should be of the leather gauntlet type with
canvas or leather cuffs, as specified in IS :
* When molten metal or hot particles are emitted during welding, the
welder should wear a leather apron to protect his clothing.
1. Sparks from welding and particularly from gas cutting can travel a
considerable distance.
3. Do not weld out tanks or vessels which may have contained petrol,
oils, spirits or any other inflammable or explosive material without
make it safe. They should be washed out thoroughly with caustic soda
or carbon tetrachloride and then with water. If possible pass steam
also.
10. It is the operator’s duty to adequately protect his own clothing and
person from sparks, flying particles of incandescent metal or slag.
Never wear oily or greasy clothing of any kind.
11. For work at more than 5 ft. above the floor or ground, use a
platform with railings, or a safety belt and lifeline.
15. Follow safe house keeping principles, Do n’t throw electrode or rod
stubs on the floor - discard them in the proper waste container. Keep
tools and other tripping hazards off the floor - put them in a safe
storage area.
17. Before starting, sweep floors clean, wet down wooden floors, or cover
them with sheet metal or equivalent. In outside work, don’t let
sparks enter doors or windows.
19. Station extra men with hose, extinguishers, or fire pails to watch
sparks and see that they do not start fire.
21. Don’t use the equipment near flammable liquids, or on closed tanks
which have held flammable liquids or other combustibles. Remove
inside deposits before working on ducts.
23. See that the fire service should be called at the first sign of fire.
24. Cutting and welding operators, and every other person concerned,
shall be instructed to watch for and be ready immediately to
extinguish any fire that may occur and know how to transmit a call to
the nearest fire station.
ANNEXURE
CHECK LIST
13. Are clamps and clips are used only for tying
up of welding hoses?
Noise also makes it difficult to hear sounds that you need to hear such as
work signals and warning shouts.
There are several steps that can be taken on site to reduce noise:
• Check that exhaust outlets are fitted with silencers or mufflers, and do
not keep machinery running unnecessarily.
• Keep compressor motor covers closed when they are running.
• Check that concrete breaker mufflers and similar devices are securely
fitted.
• Check that machinery panels are secured and do not rattle.
• Ensure that sound-insulating screens are provided to reduce noise
from stationary plant, and that where practicable noisy machinery is
sited behind earth mounds or brick stacks to isolate or screen it as far
as possible.
10.1.1.3 Vibration:
10.1.2 Illumination:
All parts of the site need to be properly lit by natural or artificial means
whenever work is going on. Site lighting is always necessary in those
areas short of natural light such as shafts and enclosed stairways.
Artificial lighting should be placed to avoid deep shadows - these may
conceal hazards which would be obvious in good light. Mounting of lights
should be as high as practicable to avoid glare, and lights should be
placed so that workers do not have to work in their own shadow.
Only robustly installed fittings which are well out of reach, such as
floodlighting, should be used and operated at full mains voltage.
Temporary electric lighting should be installed by trained electricians
using low-voltage equipment.
Ensure that the following are followed by workers:
• Make sure that cables are fastened well off the ground and do not let
cables or connections trail in wet conditions.
10.1.3 Ventilation:
Good welfare facilities are essential to health in hot climates, and the
suitable arrangement of working time is important. There should be:
- Workers repeatedly using vibratory tools such as rock drills may suffer
"white finger" syndrome involving sensory loss as a consequence of
cold.
- Wind can affect temperature. When the air temperature is 100 Celsius
and the wind speed is 32 km per hour, the temperature, so far as the
body is concerned, falls to freezing. This is called the chill factor.
Even where the temperature is above freezing point, a condition called
"immersion foot" can occur in wet conditions if the feet are not kept
dry.
- Choose clothing which allows moisture to escape but does not allow
wind and rain to penetrate: waterproof clothing tends to prevent
evaporation of moisture.
- Use facilities for preparing hot meals and drinks, and for storing and
drying clothing.
Annexure -1
SCHEDULE-VI
PERMISSIBLE EXPOSURE IN CASES OF CONTINUOUS NOISE
(See rule 34)
Introduction:
Workers should be encouraged to use PPE and should receive some type
of sanctions if they fail to wear the equipment. Companies can increase
compliance by enlisting the aid of line supervisors and managers, letting
employees have some choice in the type of equipment purchased, and
establishing a sound training program with consistent enforcement of all
rules and regulations.
Safety glasses and goggles should be large enough to shield the entire
eye socket area and should contain lens materials matched to the hazard
worker’s face, particularly for laser and welding operations. Hoods can
provide protection against chemical splashes. Both eye protection
devices and face shields must be kept scrupulously clean to avoid
contaminating the surface of the eyes or face.
Passive fall protection systems include personal and debris nets placed
beneath work areas to catch workers or falling debris. These nets can be
combined to serve as both personnel and debris nets for the same job.
Active fall protection systems include secure anchorage points and the
use of lanyards, safety belts, fall arresters and shock absorbers,
harshness retracting lifeline devices, horizontal and vertical lifelines, and
hardware connectors.
Annexure – 1
A SAFETY HELMET
Fibre glass HDP etc should weigh 400 to 450 gms and be
moisture shock and fire resistant. It should withstand 20 deg
and plus 50 deg. C. If a plumb bob of 500 gms weight with
conical steel point is dropped from a height of 3M there should
be no piercing or denting.
B SAFETY BELT
C GOGGLES
(b) For welders / gas cutters heat proof unbreakable zero power
smoke colour glass of suitable shade according to the type of
hob with protective clear glass. The fibre frame should have
provision for side ventilation padded cup edge, leather
covered nosepiece, fitted with elastic headbands and
conformable to use.
D GLOVES
(a) All leather made of chrome / calf leather 450 mm long with
five fingers double stitching for joints. The fit of gloves
should be such that the fingers have ample room and the
bridge connecting the thumb to the gloves should be
sufficiently deep so that the thumb will not cause strain on
the palm of the gloves. Stitching should be done with good
quality thread.
E DUST MASK
Cloth dust mask flannel type made from netting cloth outside and
fine canvas cloth inside sandwiched with 3 mm foam padding,
enclosing the mouth and the nose, with elastic head strap ensuring
safe breathing in dusty atmosphere.
F SAFETY NET
H EAR MASK
1. Duration of training.
2. Frequency to training.
3. Responsibility and arrangement of first aid training.
4. Maintenance of records.
5. Placement of first aid boxes.
6. Contents of first-aid box.
7. Minimum No. of trained first aiders.
2. RCM/RCE shall check and sign all registers pertains to first aid once
in every fifteen days.
Annexure - I
The first aid shall be distinctively marked with a red cross on a while
background and contain following:
Medicines
17. Caps. Amoxyciline 250 mg. (300 Nos.) 1Cap.Three times a day.
18. Tabs. Althrocine 250 mg. (100 Nos.) 1 Tab four times. a day
19. Tabs. Ibugesic plus. (500 Nos.) 1 Tab 3 times a day.
20. Tabs. Polycrol forte (PFT) (500 Nos.) 1/2 Tab at a time to be
chewed 2/3 times a day.
21. Tabs Metrogyl Compound (500 Nos.)/ 1 Tab. 3 times a day X 5
days.
22. Tabs Neobarb/Entro-quinol 1 Tab 3/4 times a day.
23. Tabs Domid (200 Nos.) 1 Tab 2 times a day.
24. Tabs Polaramine (200 Nos.) 1 Tab 2 times a day.
25. Tabs Avomin (100 Nos.) 1 Tab 2/3 times a day.
26. Tabs Vikoryl (300 Nos.) 1 Tab 3/4 times a day.
27. Tabs Crocin (500 mg) (500 Nos.)/ 1 Tab 3/4 times a day.
Annexure - II
INSTRUCTIONS
Annexure - III
General :
Electrical Injuries:
Current flow and time are the factors that cause injuries in electrical
shock. The severity of electrical shock is determined 1) by the amount of
current that flows though the victim (Table 1), 2) by the length of time
that the body receives the current and 3) the part of body involved.
But current flow depends on voltage and resistance, these factors are
also important and if it is alternating current frequency. Heat is a
secondary effect on the body. Such current flow can easily be received on
contact with low voltage sources of the secondary lighting or power
circuit.
A person’s main resistance to current flow is the skin’s surface. Dry skin
has a fairly high resistance. A sharp decease in resistance takes place
when the skin is moist (Table 2). Once the skin’s resistance is broken
down, the current flows readily through the blood and the body’s tissues.
The resistance decreases rapidly with increase in voltage. Low voltage is
dangerous as it prevents the victim from breaking the contact with the
circuit.
Internal Injuries:
Death or injuries from electrical shock may result from the following
effects of current on the body:
1. Contraction of the chest muscles, which may interfere with
breathing to such an extent that death will result from asphyxiation
when the contact is prolonged.
2. Temporary paralysis of the nerve center, which may result in failure
to breath, a condition that often continues long after the victim is
freed from the circuit.
3. Interface with the normal rhythm of the heart, causing ventricular
fibrillation. In this condition, the fibers of the heart muscle, instead
of contracting in a coordinated manner contract separately and at
different times. Blood circulation ceases and unless proper
resuscitation efforts are made, death occurs. The heart cannot
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• At the design and planning stage, and as the project develops, issues
which need to be considered or reviewed will include the following:
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Staff Appointments:
Generators:
A supply from electrical board is not always available. In these instances
the electricity supply for the site can be provided by an ac generating set.
Care is needed to ensure that the generator is installed safely and expert
advice may be needed particularly on earthing.
For small-scale work, or in locations remote from the site supply, portable
generator (with outputs of up to 10kVA) are often used. For short time
work (e.g. less than one day), these generators need not be earthed
provided that they are only used with ClassII (double insulated or all –
insulated) tools or equipment.
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The smaller, single phase generators used for 110V supplies, (i.e. those
with ratings up to about 5kVA) need not be earthed, if all the equipment
in use is double insulated, or if it is supplies only one item of “earthed”
equipment. However, the equipment should be bonded with the frame of
the generator. (Bonding involves connecting items of metalwork together
in a way that is electrically continuous.)
Earthing:
Electrical safety often depends upon the existence of effective earthing.
The responsibility for ensuring that the electrical earthing is effective
rests with the person in charge of the site, not with the electricity
supplier.
" If extension leads are used, it is strongly recommended that these are
always of three core construction having a separate protective
(earth) conductor. This will ensure that the supply to tools, which
are not double insulated, always includes an earth.
" This is the cabling system and equipment installed to distribute and
supply electricity to points of use at the various locations on the site
during the construction phase. The temporary site distribution
system is always removed when site work is completed, as it is then
no longer required. Removal may begin on completion and
commissioning of all or part of the permanent, fixed installation.
" Although the site distribution system may be only temporary, the harsh
conditions on site require that it is to a high standard. Equipment
must be adequately protected against damage and contamination
due to dust etc.
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" The use of correctly rated fuses and / or circuit breakers is essential for
all the supplies on site.
" Makeshift arrangements, such as unprotected wiring, taped and twisted
cable joints, are often dangerous and should not be permitted. All
wiring on site should be installed to appropriate standards.
" Distribution cables should be located where they are not likely to be
damaged by site activities. They should be kept clear of
passageways, ladders and other services. If they need to cross a
site roadway or walkway they can be put into ducts with a marker at
each end of the duct. If the roadway is used by vehicles, the duct
should be at least 0.5m below the surface. A record of the location
any underground cables, using maps or plans showing the line and
depth of such cables will be invaluable in avoiding damage as work
progresses. Alternatively, cables properly protected can be carried
at a suitable height above the roadway or footway. A goalpost type
system may be required.
" All fixed distribution cables which carry 400V or 230V on a construction
site are recommended to be of a type which has metal sheath and /
or armour which is continuous and earthed. The metal sheath and /
or armour should be protected against corrosion.
" Site offices and fixed floodlighting will generally require 230V supplies.
Installation within site offices and the other buildings should be to a
suitable standard. The equipment should be suitable to the
surrounding enviroment.
" It is strongly recommended that, on larger sites, any existing or new
permanent fixed supply contractors’ equipment during the
construction work. This will minimise unauthorised interference with
the permanent fixed installation.
Moveable Plant:
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" Plant such as lifts and hoists, which may be relocated occasionally
during the work, is recommended to be supplied by armour cable.
If, in the course of the construction operations, the plant is to be
relocated, a safe method of work must be adopted. This will include
turning off the supply and disconnecting the cable before the plant
and cables are moved. Plant which is moved frequently (e.g. a
cement mixer) should be connected to the supply by a flexible cable
with protective braid and abrasion-resistant sheath. Cables will need
to be suitably located and adequately protected so that they will not
be damaged.
" If equipment has a high current requirement (current ratings greater
than 16 amps), arcing can occur if the plug and socket are
separated under load, causing burn or other injuries. Ways of
isolating the supply should be provided to ensure that the supply is
switched off before the plug and socket are separated.
Portable Equipment:
" Portable equipment and its leads face harsh conditions and rough use.
Equipment is likely to be damaged and may become dangerous.
Modern double insulate tools are well protected, but their leads and
plugs are still vulnerable to damage and should be regularly
checked. It is essential that the type of equipment selected is
suitable for use on a construction site, and that any restrictions on
use given by the manufacturer are followed.
" The site supply voltage will often influence the choice if equipment.
Where the supply is 230V or above, contractors can themselves
eliminate or reduce the risks by selecting cordless tools or tools,
which operate, from a reduced low voltage supply, (e.g. 110V
systems which are center tapped to earth). For lighting, lower
voltages can be used and are even safer.
" There have been fatal accidents where 110V equipment fitted with plugs
designed for a 230V system or damaged.110V plugs have been
plugged into 230V supplies. To avoid danger, plugs and sockets
used on the reduced low voltage system should not be
interchangeable with 230V (mains) plugs and sockets. These
industrial plugs and sockets are more robust than domestic type
equipment, which is not designed for use on construction sites.
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" Cables with solid conductors (non-stranded) are designed for use in
fixed installations. The conductors inside are brittle and liable to
break if bent, so they should not be used as either extension leads
or replacement cables for portable equipment.
" When main voltage equipment is used on construction sites, the risk of
injury or death arising from the use of damaged or faulty
equipment, leads or plugs is unacceptably high unless special
precautions are taken. The precautions must reduce the risk to an
acceptable level taking into account the constraints regarding RCDs
mentioned in following paragraphs. Reasonably practicable
precautions include:
(b) Reducing the risk of flexible supply leads being damaged by:
(c) Selecting tools that are designed for trade and work use.
Double insulated equipment is strongly recommended where it
is necessary to use a main voltage supply, because the tools
themselves are less likely to give rise to danger. (Danger can
still arise, however, if the cables, plugs or equipment casing
are damaged). Any restrictions on use out in the
manufacturer’s instructions should be observed.
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" The outer cover of the equipment is not damaged or loose and
all screws are in place.
" There are no overheating or burns marks on the plug, cable or
the equipment.
" It is serviced regularly in line with the manufacturer’s
instruction.
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Annexure – I
General Precaution
" Implement lockout / tagout procedures prior to performing any electrical
work.
" Make dielectric tests on rubber gloves and blankets at regular intervals.
They should be air tested daily before use and kept powered.
" Notify all personnel concerned before starting any electrical equipment.
" Always assume a circuit is energised until you have checked it.
" Do not energise a tagged starter or switch without first properly
removing the ‘lock-out/tag-out’.
" Always remove the load from a circuit before de-energising it.
" Ventilate the working area well and keep fires and sparks away from
charging batteries since the acid fumes explode as hydrogen gas is
generated while charging a battery.
" Never use water on an electrical fire.
" Never look directly at open switches or breakers when energising or de-
energising to avoid retinal burns.
" Only trained authorised personnel should perform maintenance and
repair work on electrical equipment.
" When repair work on energized circuits must be made, the following
precautions must be taken:
" Never pull any fuse that is carrying current. Never break a circuit under
load, severe arcing may occur.
" Use approved tools and “hot” circuit handling equipment when working
on energized equipment. Be thoroughly familiar with the circuit to
be worked on.
" Personnel should be stationed near the main switch or circuit breaker so
that the equipment can be de-energized immediately in an
emergency.
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" Metal ladders and scaffolds are electric conductors, they should never be
used around electric circuits or in place where they can come in
contact with electrical circuits.
" Extension cords should not be tied to electric outlets. These cords must
be free so they can be unplugged in an emergency.
" Use hand line when raising or lowering tools. Never lower electrical tools
by the cord.
" Cable trays are not designed to support loads, to be walked on, or used
to secure safety belt lanyards.
" Always de-energize circuits before attempting to reset them.
" Follow the following safe work practices:
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Annexure - II
Where for both Tables 2 and 3 conditions (I), (II), and (III) are as
follows:
(I) Exposed live parts on one side and no live or grounded parts on the
other side of the working space, or exposed live parts on both sides
effectively guarded by suitable wood or other insulating materials.
Insulated wire or insulated busbars operating at not over 300 volts
shall be considered live parts.
(II) Exposed live parts on one side and grounded parts on the other side.
(For Table II; concrete, brick, or tile walls will be considered
grounded surface).
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(III) Exposed live parts on both sides of the workspace (not guarded as
provided in condition (I)) with the operator between.
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Annexure - III
Overhead Lines:
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Annexure – IV
Table 2
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The types of testing most commonly used for forged and cast metals
are the following:
1. Magnetic Particle Inspection
2. Penetrant Inspection
3. Ultrasonic Methods
4. Triboelectric Method
5. Electro-magnetic Tests
6. Radiography
13.1 Radiography
Radiography uses x-ray and gamma rays. X-rays are unidirectional and
their wavelengths can be varied, within certain limits, to suit the
In addition, X ray units involve both low and high potential electrical
hazards.
Isotopes
Curie :
Radiography of a source is measured in terms of numbers of
transformation it undergoes in one second. The unit for radiography is
Curie. Which is corresponding to 3.7*1010disintegration per second.
Curie shows the strength of the material.
Unit used for exposure is Roentgen (R)
The special unit of equivalent ionising dose presently used is Sievert
(Sv).
1 Sv = 100 R (Roentgen)
Dose Limit :
Since radiation causes undesirable effects on the body tissue. It is
important to observe the maximum permissible levels of radiation,
which have been recommended. International commission on
Radiological Protection (ICRP) sets guidelines in the form of annual dose
limits to individual. Setting dose limits below the threshold dose limit
(maximum permissible limit) can prevent any effects due to radiation
Permissible limit:
Time:
The radiation dose received by person depends on the total time spent
by the person near the source. Lesser the time spent near the source,
lesser would be the radiation dose.
Distance:
Larger the distance, lesser will be the radiation level. The most
economical and effective method of reducing the radiation hazard is to
increase the radiation distance between the radiation source & person.
Shielding:
8. Ensure that all walls, floors, ceiling & doors is having sufficient
shielding so as to minimise radiation level below the
recommended limit.
2. Lock the camera to ensure that the source assembly would not be
released.
10. The operator should be aware of the dose record and send the
records for periodic medical examination.
Abrasive blasting
Airborne dust
Metal dust:
Silica sand:
This product is a potentially serious health hazard and should not be used
as an abrasive. If silica containing (quartz) materials are selected for
any reason, workers must wear a positive pressure or pressure demand
respirator with an assigned protection factor (APE) of either 1000 or
Air supply:
These fully enclosed cabinets are designed to filter out dust and re-use
blasting medium.
Spray Painting
Hazards
Inhalation of mists and vapors from nearly all paints, solvents, thinners,
cleaning chemicals, strippers, and epoxies can be injurious depending
upon the agent's toxic characteristics and the amount and method of
exposure.
Further, many paints can physically injure the skin and eyes, or be
absorbed through the skin. Potential physical and health hazards can be
effectively controlled by appropriate work procedures, controls, facility
design, protective clothing, and equipment.
Safety
1. Pressure Equipment
2. Other Equipment
3. Paint Mixing
4. Housekeeping
Health
1. Personnel Exposures
2. Protective Equipment
3. Personal Hygiene
The hands and face shall be kept clean, clothes shall be changed when
contaminated.
No food or drink shall be brought into, or consumed, in paint shops.
Personnel shall wash their hands prior to smoking or consuming food.
5. Fire Fighting
Portable fire extinguishers should be installed near all areas where spray
painting is carried out.
6. Ventilation Systems
It is desirable that the floor of paint spray booths be covered with a non-
combustible mat, removable for cleaning or disposal.
The same general safety and health precautions apply to spray painting
from pressurised cans as to spray painting by other means.
Introduction
Soldering irons can be the source of burns and illnesses that result
from inhaling fumes. Soldering irons must have adequate holders to
prevent accidental burns and workers have proper protective gear
and ventilation to eliminate vapor and fume hazards.
• Air powered tools include air hoses, grinders and pneumatic impact
tools. To prevent injuries associated with air hoses, workers should
make sure hoses do not present tripping hazards, avoid using
hoses as cleaners and prevent accidental disconnection of hoses
from the tools. Air-powered grinders require the same type of
guarding as electrical grinders.
• Some does and don’ts using power tools are listed in Annexure – 2.
Annexure – 1
Inspection Checklist
GENERAL
CORDS
GROUNDING
GUARDING
Annexure - 2
- Familiarity Breeds
Injuries
A. Hand Tools:
1. All tools and Equipment (Both company and employee owned) used
by employees should be in good condition.
2. Hand tools such as chisels, punches wedges or drift pins which
develop mushroom heads during use, it's heads might shatter on
impact, sending sharp fragments flying should be recondition or
replaced.
3. Broken, loose, splintered or fractured handles on hammers, axes and
similar tools, the head of the tool may fly off and strike the user or
another co-worker. Tool handles should be replaced promptly and
wedged tightly in the head of all tools.
4. Worn, bent or sprung jaws spanners and wrenches, which slip during
use, should be replaced regularly.
5. Appropriate handles should be used so the operator's wrist can
remain in a natural position for files and similar tools. (Selection
depends on the relationship between the work surface height and
operators elbow height.)
6. Employees to be made aware of the hazards caused by faulty or
improperly used hand tools.
B. Power tools:
Annexure – 3
Workers using revolving tools such as drills saws and grinders should not
wear ties, gloves loose clothing and jewelry. Clothing should be free of
oil, solvents or frayed edges to minimize the fire hazard from sparks.
The weight of most power tools makes i9t advisable for users to wear
safety shoes to reduce the chances of injuries should the tools or work-
piece fall or be dropped.
When power tools are used in overhead places, the operator should wear
fall-protection devices to minimize the danger of falling, should be tool
break suddenly or shock the operator or should the operator slip. Also,
attach a safety line to the tool to keep it from falling on persons below
should it be dropped.
On buffing, grinding and sanding jobs that produce harmful dusts provide
workers with approved dust-type respirators. For operators of powder-
actuated tools or hammers, provide hearing protection if more positive no
controls are possible.
In all operations where striking and struck tools are use or where the
cutting action of tool causes particles to the provide eye protection that
conforms to ANSI Z87.1 Practice for Occupational and Educational Eye
and False Protection. Minimize the hard of flying particles by using
nonferrous, soft striking tools and shielding the job site with metal, wood
or canvas. However, eye protection still required.
Wear eye protection or face shields when using wood working or cutting
tools such as chisels, brace and bits planes scrapers and saws. There is
always the chance of particles falling or flying into the eyes. Also wear
eye protection or face shields when working with grinders buffing wheels
and scratch brushes. The unusual positions in which the wheel operates
may cause particles to be thrown off in all directions. For this reason,
eye protection is even more important than it is when working with
stationary grinders.
Annexure – 4
Do’s
1. Work area must be well lighted.
2. Always cut away from your body.
3. Avoid scattered tool near work place.
4. Pass a tool to another person by the handle.
5. Use the right tool in the right size for the job.
6. Always pull on the wrench. Never push against it.
7. Be on the lookout for signs of repetitive stress. Early detection
might prevent a serious injury.
8. Keep floor area clean and dry to prevent accidental slips while
working with or around dangerous hand tools.
9. Carry tools securely in a tool belt or box. Use a hoist or rope.
10. Make sure your grip and footing are secure when using large tools.
11. Check jacks periodically to ensure that they are in good condition.
12. Secure work with clamps or a vise, freeing both hands to operate
the tool.
13. Keep close track of tools when working at heights. A falling tool can
kill a co-worker.
14. Select ergonomic tools for your work task when movements are
repetitive and forceful.
15. Replace or redress tools heads that might shatter on impact
sending sharp fragments flying.
16. Store tools in dry and secure locations were they wouldn’t be
tempered when you stop work.
17. Use the right personal protective equipment (PPE) for the job.
Follow L & T’s safety manual for selecting and using safety
eyewear, steel toed shoes, gloves, hard hats, etc.
Don’ts
1. Don't carry tools up ladders.
2. Never toss tools to another person.
3. Never apply unnecessary pressure when using tools.
4. Don't use your wrench as a hammer & screwdriver as a chisel, etc.
5. Never carry sharp or pointed tools such as a screwdriver in your
pocket.
6. Don’t use worn, bent or spung jaws spanners and wrenches that
may slip during use.
7. Don't use broken, mashroom head or damaged tools, dull cutting
tools, or screwdrivers with worn tips.
8. Never use blunt tools, which is more hazardous then sharp tool as
sharp cutting edge move smoothly without bending or skipping.
9. Never use tools having broken handle. Replace handles promptly
and wedged tightly in the head of the tool. As that may fly off and
strike the user or another co-worker.
10. Never use iron and steel hand tools which produce sparks around
flammable substances. Use spark resistant tools made from brass,
plastic, aluminum or wood.
By following these precautions, you can help prevent injuries and provide
a better workplace for everyone.
Power tools are handy helpers that people use for a variety of purposes in
all settings. They come in different styles and sizes. These tools are
useful time savers, but they're also deceptive. They can deliver a
paralyzing, or even deadly shock. They can slash, cut and mangle,
sometimes easier than larger, stationary machines.
Do’s
1. Keep cords away from heat, oil and sharp edges.
2. Choose the right tool for the job; inspect it for damage and
adjustment and make sure all guards are in place.
3. Disconnect tools when not in use, before servicing and when
changing accessories and locked before put to use.
4. Operate electrical tools within their design limitations and test them
before putting into use.
5. Be sure switches are in the off position before you plug tools into an
outlet.
6. Make sure the power tool has stopped running before placing it on
the ground or a surface that you're working on.
7. Always check the condition of cords for deterioration or damage.
8. Keep fingers well away from switches or buttons when tools are not
being used, and unplug or deactivate tools not in use. A power tool
can be turned on accidentally, penetrating a hand, arm or leg.
9. Use proper PPE - such as safety glasses when cutting, a dust mask
when creating dust and hearing protection when noise levels are
high.
10. Keep all observers at a safe distance away from the work area.
Remove from use all portable tools those are damaged and tagged
“DO NOT USE”.
11. Only 3-prong grounding extensions are to be used for equipment
and plugs must be matched with outlets.
12. When working in wet areas or areas that contain flammable liquids
use only specified approved tools.
Don’ts
It's easy to forget the potential dangers of power tools because they are
usually small, portable and commonly found around the shop. Many times
they're not treated with enough respect, and they are frequently left lying
around in unsafe places.
Power tools are invaluable, timesaving devices when used properly, but
careless or improper use can cause severe injury or death. Always follow
safety instructions when operating power tools
Annexure – 5
Air powered tools present many of the same hazards as their electrically
powered counterparts, Electrical tools are powered from a source that
provides a well-regulated standard current. However, with air powered
tools, air may be delivered at varying pressures, flows and plus hazards
you may not have considered. Here are things to remember when using
air tools:
Do’s
1. Adjust your air pressure to the manufacturer's rating.
2. Make sure hoses are of the correct inside diameter and are not kinked
or crushed.
3. Your compressor and receiver must have enough capacity to deliver
air in an amount sufficient to properly operate all attached tools.
4. Installed effective mufflers on the air exhaust at the tool itself or
nearby or worn hearing protection from prolonged exposure to muffled
loud noise of pneumatic tools can be much noisier than electric tools.
5. Frequently wipe both your hands and the tool, if oil-contaminated air
discharges near where you grip the tool.
6. Use hand gloves to avoid frostbite, stiffen your fingers, or even make
you more susceptible to certain types of cumulative trauma injuries by
cold air discharges on your hand.
7. Protect the hose from physical damage, as you may injured by
violently whipping air hose around or while scrambling to get out of its
way until the air is shut off.
8. Use goggles to protect your eyes from compressed air or particles may
fly from equipment such as chipping hammers, rock drills, rotary drills
or sanders, which cause pain or injury.
Don’ts
Contact dermatitis may result from the contact between the skin
and some chemicals. Acids and alkalis are corrosive and can
damage both skin and eyes.
This is the most important route of entry. Some toxic gases and
vapours cause irritation in the nose and throat and so give warning
of their presence others do not, and penetrate to the lungs or blood
Ingestion or swallowing:
Some solvents can be absorbed through the skin into the blood
stream and may travel to internal organs such as the brain and
liver.
Contact Dermatitis:
Preventive measures:
Accidents and ill health from the use of chemicals can be prevented
if we know what chemicals we are using and the risks they pose,
and follow the established safe practice in handling them.
Generally, there is an order of priority in the measures for dealing
with hazardous chemical substances.
• Substitute the chemical with a harmless or less hazardous one.
- Keep containers in the store until required for use, and return
them there when you have finished with them. Store drums
upright.
- Treat empty drums with as much care as full ones - they will
still Contain flammable vapour.
Hazardous substances:
Cement:
- Protect the eyes., if any cement gets into the eyes, rinse them
immediately with plenty of warm water.
Asbestos:
In many countries those who work with asbestos to any extent, and
in particular in removing and disposing of asbestos, require to be
licensed or to hold a permit. In working with asbestos insulation
board, workers will probably need to wear suitable protective
clothing. Only working methods that keep asbestos dust levels as
low as possible should be used (e.g. use hand tools and avoid
breaking boards).
When cutting asbestos cement, use hand tools (or power tools
fitted with exhaust ventilation equipment). Where it is not possible
to keep asbestos dust levels under control limits, respirators should
be worn. Protective clothing will probably be required for any
significant work with asbestos cement. If you have to clean
asbestos cement sheeting encrusted with lichens or mosses, a
system of wet scraping/brushing is preferred.
Lead:
Apart from the most common materials listed above, the site uses
many other chemicals with varying quantities during construction
and commissioning of the project. Listing all the details of all these
chemicals in this manual is not practicable.
The user should familiarise with the details and equip himself to
tackle any of the emergency listed in the MSDS.
The MSDS of some of the commonly used chemicals, acid and alkali
is given in the annexe.
17 Fire Prevention
Introduction:
Fire Protection:
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Some general facts about fire protection that must be kept in mind
follow:
• No facility is absolutely fireproof. Nearly everything can
burn, given ignition, adequate fuel and sufficient oxygen.
• Heat energy is transmitted by convection, conduction and
radiation.
• Fire and flame will spread in a building both vertically and
horizontally.
• The spread of the heat, smoke and toxic gases is possibly the
greatest single danger to life and takes place in much the
same manner as does the spread of fire. Smoke and toxic
gases are responsible for 66% of deaths from fire in
buildings.
• Onsite early detection of a fire is absolutely essential.
Fire Prevention 2
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Fire Prevention
Fire Prevention 3
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Knowing how and why a fire burns suggests ways to control and
extinguish it. The surface fire has three components that can be
controlled, while the flame fire has four components. Fires can be
controlled in the following ways:
• Heat can be taken away by cooling.
• Oxygen can be taken away by excluding the air.
Fire Prevention 4
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Cooling a Fire
Often taking the fuel away from a fire is not only difficult but
dangerous. Fortunately, there are exception (1) Storage tanks for
flammable liquids may be arranged so their contents can be
pumped to an isolated, empty tank in case of fire. (2) When
flammable gases catch fire as they are flowing from a pipe, the fire
will go out if the fuel supply can be shut off. (3) In any mixture of
fuel gases or vapors in air, adding an excess of air has the effect of
diluting the fuel’s concentration below the minimum combustible
concentration point.
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Covering a fuel, however, can stop a fire. Much foam and some
solids serve as an emulsion film, or cover, on the burning fuel, thus
extinguishing the fire. If the contents of a wastebasket catch fire,
drop an empty wastebasket on top of it to smother the fire.
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Fire Prevention 7
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Classification of Fires
Class A Fires
Class B Fires
Class C Fires
Fire Prevention 8
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Class D fires
Other Fires
Fire Fighting
When all the above measures fail and a file occurs, to minimise its
effect there should be an efficient the fighting system consisting of
fixed system like the hydrants portable extinguishers and trained
personnel to man these facilities
Since all the sites do not have fixed the fighting system, portable
extinguishers are highly relied up on.
Fire Prevention 9
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Principles of Use
Fire Prevention 10
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Fire Prevention 11
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Location of extinguishers
Fire Prevention 12
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Make plant and warehouse aisles wide enough (1) so that mobile
fire protection unit can be brought close to a fire and (2) so that
aisle can be kept free of obstructions. Mark floor spaces to allow
access to fire extinguishing equipment, and protect extinguishers
with bumpers or guardrails.
Distribution of extinguishers
Selection of Extinguishers
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Fire Prevention 14
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Annexure – 1
Remove safety catch strike the plunger against hard surface which
process either the glass bulb in case of soda acid extinguisher or
carbon dioxide cartridge.
Fire Prevention 15
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Annexure –2
Type of Extinguishers
Fire Prevention 16
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Introduction
Definition:
Scope:
Much of the earlier part of this manual has been concerned with
preventing accidents through supervision. Achieving this will reduce
the risk of an accident, but it will not eliminate it altogether.
Complete safety is not achievable, and an essential part of major
hazard control is concerned with minimising the effect of a major
accident.
An important element of mitigation is emergency planning, i.e.
recognising that accidents are possible, assessing the consequence
of such accidents and deciding on the emergency procedures both
on site and off site, that would need to be implemented in the
event of an emergency.
Emergency planning is just one aspect of safety and cannot be
considered in isolation. In particular it is not a substitution for
maintaining good standard inside thee works. Before starting to
prepare the plan, works management should ensure that the
necessary standards, appropriate to the safety legislation, are in
place.
Emergency plans are likely to be separate for on site and off site
matters, but they must be concurrent with each other, i.e. they
must be addressed to he same assessed emergency factors. While
on site plan will always be the responsibility of the works
Objectives:
The plan should set out the way in which designated people at the
site of the incident can initiate supplementary action both inside
and outside the works at an appropriate time. An essential element
of the plan must be the provision for attempting to make safe the
affected unit for example by shutting it down. On a complex site,
the plan should contain the full sequence of key personnel to be
called in from other sections or from off site.
Alarm systems vary and will depend on the size of the works. These
should be an adequate number of points form which the alarm can
be raised either directly, by activating an audible warning, or
indirectly, via a signal or message to a permanently manned
location. The alarm should alert the incident controller (subsection
18.2.3.), who should possess the situation and implement
appropriate emergency procedures. In area where there is a high
level of noise, it may be necessary to install more than one audible
alarm transmitter or flashing lights. Automatic alarms may be
appropriate on some sites.
Apart from these personnel other works personnel will have key
roles to play in the implementation of the emergency plan. These
Action on site
Annexure-1
Do’s
Dont’s
1. Do not panic.
2. Do not communicate with any external unless instructed by the
Site Controller.
3. Do not spread unauthorized or exaggerated information to others.
4. Do not approach the emergency site as a spectator.
5. Do not engage unnecessary the communications aids like
telephone / Public Address Systems (PAS) and other means to
make the same available for handling emergency.
6. Do not disturb the leader assigned with specific work for handling
emergency.
Annexure-2
Mock Drill will be monitored. After each drill the plan will be thoroughly
reviewed to take account of omission or shortcomings and updated
response time for each action will be noted and studied for any
improvement.
Environment Protection
In the construction site adequate measures are taken not only to fulfill all
the statutory requirements but also to conform to the norms laid down in
ISO 14001 for certification.
• Emissions to air
• Releases to water
• Waste management
• Contamination of land
• Use of raw materials and natural resources
• Other local and community issues
The last two issues, namely, use of raw materials and natural resources
and local and community issues will have to be dealt by the client and
Environmental Protection 1
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the local authorities. The E & C ‘s role in these to identify areas and
suggest remedial measures to the client for consideration and
implementation. The action to be taken at the site on the other 4 issues
is briefly described in the following paras.
The three remaining aspects namely air, water and soil pollution are to
be considered and incorporated in the system so that, at any given time,
the pollutants under the above 3 categories do not exceed the statutory
limits.
AIR POLLUTION:
At the site, blasting, excavation, piling and concreting operations are the
essential activities undertaken and these provide air pollutant in the form
of dust.
During blasting the explosives are placed in such a manner that the
debris fall within the site limits. In the site itself, the blasting area is
cordoned of so that the falling debris does not harm the workers.
As regards using the Diesel Generator sets, it is ensured for the proper
performance of the set so as to keep the pollutants, Sulfur di oxide and
Carbon monoxide level below the prescribed levels.
WATER POLLUTION:
At the site, the water pollution can occur due to following reasons:
The wastewater from the washing facility is drained through a soak pit.
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Since all these work are done through contractors, the solid waste
from the canteen is collected and disposed off.
SOIL POLLUTION:
From the above measures most of the pollutants are prevented from
getting absorbed by the soil. However the earth removed due to
activities like excavation etc; are used for levelling the ground for
making garden / planting of trees.
Environmental Protection 3