Hindustan Zinc Limited Chanderiya Lead Zinc Smelter Scaffold Safety Procedure

Hindustan Zinc Limited
Chanderiya Lead Zinc Smelter

Doc No. : HZL/CSRP/CLZS/SOP/002 Date of First Issue: 16.05.2015
Revision Number: R-01 Last Revision on: 01.09.2017
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1. Introduction:
Scaffold, a temporary structure made up of metal frames or tubing, provides support
and access for workers and materials used for maintenance work, construction
industry. Scaffolding, when not constructed properly and used, can result in serious
injury and sometimes fatality.
This procedure is developed to provide information on the safe erection, use,
dismantling and maintenance of access scaffolding in the workplace. This procedure is
developed to establish mandatory requirements for practices to protect personnel from
hazards associated with erection, use and dismantling of scaffolds.
This procedure has been developed by members of SRP subcommittee and
representative from other HZL sites with guidance of experts from DuPont Safety
Resources. Various roles and responsibilities have been defined for the persons
associated with scaffolds. The practices which have been identified here are equally
applicable across all units of CLZS. This will also help in bringing about a consistency
in the process used across plants.
These guidelines will help to provide a new impetus towards achieving the best in
class safety standards. This Revision-1 release of the procedure is formulated based
on world class practices facilitated by DuPont Safety Resources.
1.1. Intent and Purpose:
This procedure is developed to cover the safe practices required for scaffold erection,
modification, dismantling, use and storage. This procedure is developed to establish
mandatory requirements for practices to protect personnel from hazards associated in
this area.
It covers role and duties of all personnel associated with scaffold erection,
modification, dismantling and use as well as the materials and tools required to
discharge their duties effectively.
2. Scope and field of application:

This procedure applies to all facilities, sections and project sites of CLZS. Roles and
responsibilities have been defined for the persons associated with the scaffold
activities. The practices which have been identified here are equally applicable across
all plants, sections within CLZS.
This procedure is applicable to all jobs at an elevation 1.8 meter and above where
permanent platform/access is not provided and where scaffolds shall be used.
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3. References:
Scaffold safety Standard,
IS: 3696 (Part 1) – 1987 (Scaffolds) Safety code of scaffolds and ladders
IS: 3696 (Part 2) – 1987 (Ladders) Safety code of scaffolds and ladders
IS: 4014 – 1967 Part 1 Code of practice for steel tubular scaffoldings – Definitions and
Materials
IS: 4014 – 1967 Part 2 Code of practice for steel tubular scaffoldings – Safety
Regulations for Scaffoldings
IS: 1161 : 1998 : Code of practice for Steel Tube structure purpose
IS: 3521 – 1999 Industrial safety belts and harnesses
Provision on scaffold under the building and other construction workers. (Regulation
on employment and conditions of service) central rules, 1998.
4. Responsibilities:
All Line Managers and their team dealing in scaffold safety are responsible for
adhering to the procedure during scaffold related activities. These include their
contractors and contract workforce.
5. Definitions:
Scaffolding Supervisor – A competent person: Who through training and/or
experience a) is knowledgeable of applicable scaffolding regulations; b) is
capable of identifying existing and predictable hazards related to the erection,
alteration, use, dismantling, storage, and inspection of scaffolding; and c) has the
authority to take prompt corrective actions to eliminate such hazards.
Scaffolder: A person who through training and/or experience is capable of
erecting, moving, modifying and dismantling scaffold.
Fabricated-frame scaffold: A scaffold consisting of a platform(s) supported on
fabricated end frames with integral posts, horizontal bearers, and intermediate
members (also known as welded-frame scaffold and sectional scaffold).
Scaffold: Any temporary elevated platform (suspended or supported) and its
supporting structure (including points of anchorage) used for supporting man,
material or both.
Supported scaffold: One or more platforms supported by outrigger beams,
brackets, poles, legs, uprights, posts, frames, casters, or similar rigid supports.
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Examples include fabricated-frame scaffold, system scaffold, tube-and-coupler

scaffold, and manually propelled mobile scaffold.
Suspension (suspended) scaffold: One or more platforms suspended by ropes
or other non- rigid means from an overhead structure(s).
System scaffold: A scaffold consisting of posts with fixed connection points that
accept runners, bearers, and diagonals that can be interconnected at
predetermined levels.
Tube-and-coupler scaffold: A supported or suspended scaffold consisting of a
platform(s) supported by tubing, erected with coupling devices connecting
uprights, braces, bearers, and runners (also known as tube-and-clamp scaffold).
Mobile (rolling) scaffold: A castor-mounted sections of tubular metal scaffolds
and are used for work on street lighting, plant etc.
Standard: A vertical or near vertical member used in the construction of scaffold
for transmitting the load to the foundation.
Ledger: A horizontal member which ties the standard at right angles and which
may support putlogs and transoms.
Putlog: A scaffold member spanning from ledger to ledger or from
ledger/standard to a building and upon which platform rests.
Transom: A member spanning across ledgers/standards to tie a scaffold
transversely and which may also support a working platform.
Brace: A member fixed diagonally across two or more members in a scaffold to
afford stability.
Bracing: Bracing is a system of braces or ties that prevent distortion of a
scaffold.
Guard rail: A horizontal rail secured to standards and erected along the exposed
edges of scaffolds to prevent workmen from falling.
Tying Wire: It is SS Wire of Minimum 3 MM of diameter. This wire can be used
to tie Plank, only in the case of circular /round scaffolding/Area design constraint
Toe Board: A barrier placed along the edge of scaffold platform and secured
there to guard against the falling of material and equipment.
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6. Procedure:
6.1. General
6.1.1 Categories and classification:
Most scaffolds fall into one of the four primary categories:

• Tube and coupler scaffold
• Suspension(or Suspended) scaffold
• Mobile scaffold
• Special scaffold
Scaffolds are classified according to their intended use as:

• Light duty
• Medium duty
• Heavy duty
If scaffolding height is more than 15 m, or it is of special nature/ type i.e. cantilever and
suspended (slung) scaffold, wooden scaffolds (for specific use only in cooling tower)
Plan/design shall be verified and certified by professional structural/ civil/ appointed
Engineer. Such professional should be authorized by Head of Engineering Services.
6.1.2 Specifications of scaffolds:
Applicable to all scaffolds:
1. All elevated structures / working platform areas should be guarded on all sides.
2. Railings and toe boards should be provided on the platform.
3. Scaffolds should be designed to support at least 4 times the anticipated weight of
men and materials.
4. Make certain that all scaffolds are in plumb and level at all times.
5. Scaffolds shall be secured from tipping when the scaffold height exceeds four times
its minimum base dimension.
6. Scaffolds must be constructed at least 2 planks wide unless location makes this
physically impossible.
7. Landing platform should be provided at every 9 meter or less.
8. The members of scaffolds should overhang not less than 6" on either ends but not
more than 12". They should be fastened on both ends and laid tight by scaffolds and
clamps.
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Applicable to Tube-and-coupler scaffold
9. Minimum height of first horizontal member (Ledger) of scaffolds from the

Ground/Kicker lift member shall be 2.2. Meters. When scaffold is more than 6
meter height or carrying heavy load, kicker lift should be provided.
10. The mid rail and Top rail shall be at height 580mm and 1050mm respectively and toe
boards (150mm) should be securely attached to the platform.
11. Wall scaffoldings shall be secured between structure and scaffolding, at least every
10 meters of length and 8 meters of height.
12. Minimum overlap of vertical members (standards) and/ or horizontal members

(ledgers) shall be 600 mm with at least two couplers.
13. Base plate 150 x 150 x 6mm shall be used to support all vertical pipes of Scaffolds.
14. Sole plate of Metallic: “300x450x16mm or Wooden: “300x450x40 shall be used at all
unpaved area to support base plate.
15. Scaffolds should conform to IS 4014 (for steel tubular) and Pipe material should be
as Per IS :1161 1994 ,Duty Type : Medium
Applicable to Mobile scaffolds:
16. Attach castors with plain stems to the panel or adjustment screw by pins or other
suitable means. mid rail and Top rail shall be at height 580 mm and 1050 mm
respectively.
17. Apply castor brakes at all times when scaffolding is not being moved.
6.1.3 Control and handover procedure:
Scaffolding control and hand-over procedures shall be as described below:
a) The requirement of scaffolding for working at heights will be as stated in the

work permit. Based on this, the request for the scaffolding will come from the
maintenance engineer who will be the user of the scaffolding.
b) The maintenance engineer will formally request the scaffolding contractor as per
format given in Annexure-2 to erect the scaffolding.
c) The scaffolding contractor/Maintenance Contractor shall erect the scaffoldings

by complying with the conditions specified in this procedure. Besides, he shall :
d) Appoint a scaffolding supervisor (competent person).
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e) Ensure that all its employees adhere to the recognized standard or code of
practice with respect to the selection of scaffoldings, erection, dismantling and
possible modifications.
f) Provide adequate safety clothing and equipment such as helmet with chin-strap,
safety shoes, cotton hand gloves, safety goggle, full body safety harness with
double lanyard and snap hooks and ensure these are properly used.
g) Adhere to the written hand-over procedure and maintain good communication

with the maintenance engineer of HZL at all times.
h) During the erection stage of scaffolding, warning notices with the wording
“scaffold incomplete, Do not use” (Annexure-1) should be fixed to the scaffold at
all access points. This warning will be in the form of a painted board.
i) After erection, but before first use of a scaffold, the erected scaffolding shall be
inspected (Using scaffold audit check list as per Annexure-3) and approved by
the scaffold supervisor and maintenance engineer. The certification of the
scaffolding shall be as per Annexure-4. The certified scaffold shall then be
handed over to the maintenance engineer of HZL for use. Once erected the
scaffolding shall be inspected every week.
j) When the completed scaffold is handed over for use, it is the responsibility of
user to ensure its correct and safe use.
k) The status board with the wording “Scaffold Complete, Safe for Use" (Annexure
1) should be displayed when the scaffolding is ready for use.
l) In the event of any doubt concerning the integrity of a particular scaffold,

“Scaffold Incomplete – Do not use” (Annexure 1) boards to be put. These
boards will be put up after removing "Scaffold Complete- Ready for Use"
boards.
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Scaffolding Process Flow chart
Scaffold Request generation by

Maintenance Engineer
Scaffold supervisor visit the site to check/access risks as per risk assessment sheet with work
permit and scaffold request.
Make the Scaffolder aware about control measures and quantity of material to be shifted at site.
Identify location and barricade
Scaffolding completed as per

the are specification
Arrange inspection of scaffolding by Certified Scaffolding Inspector as per Annexure 03 and do

necessary correction in scaffolding if required and arrange Certification as per annexure -04
Put Green Tag on Scaffolding and surrender Scaffolding Erection Permit
Weekly Audit of Scaffolding to be done as per Annexure -05 and Signed on

back side of Green Card
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6.2. Erection, dismantling, movement and modification
Timber scaffolds shall not be used except under special

requirements.
WARNING
No erection, dismantling, movement and modification

CAUTION without valid work permit.
An assessment of hazards shall be made before erecting, dismantling, moving, or

modifying scaffold. Examples of hazards to be considered include the following:
• Working at/from heights
• The presence of nearby electrical lines or process equipment
• Hazardous area classification
• The condition and loading of working surfaces /platform
• The presence and activity of other people and equipment in the vicinity of
the work
• The weather
This assessment is a part of the work permit process but should also be extended to the
specific job planning of the crew performing the work. Appropriate actions shall be taken
to mitigate the hazards identified during the assessment.
Scaffold shall be erected, dismantled, moved and modified only under the direction
of a competent person and/or by employees who have received appropriate and
specific training for the work they are to perform.
Determination and designation of competent persons for scaffold work are the
responsibility of the Engineering In-charge and shall be addressed in contractor
SHE interface documents.
In determining competency, consideration shall be given to knowledge of scaffold
regulations, working experience, knowledge of scaffold erection, hazard at site and
training received.
Fall protection when erecting, dismantling, and modifying scaffolds shall be under
the direction of a competent person (Scaffold Supervisor). Scaffold erectors
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(Scaffolders) shall use personal fall-arrest systems that provide continuous fall
protection while erecting, dismantling or modifying scaffolds unless the
determination is made by a competent person that fall protection is not feasible or it
creates a greater hazard. Fall protection can be accomplished through the use of
adequate anchorages that are independent of the scaffold or by using scaffold
systems and components that are approved by the manufacturer as adequate
anchorages. Employees shall use appropriate fall-arrest equipment in accordance
with Engineering Standard on “Safety belts and fall protection system”
Standard scaffold planks shall not be used for purposes other

CAUTION than scaffold decking.
The footing for supported scaffolds shall be sound, rigid, and capable of supporting
the maximum intended load, including the weight of the scaffold.
Appropriate barricades shall be installed to protect people in the vicinity during
scaffold erection, use, modification and dismantling.
Manufacturer’s guidelines for proprietary scaffolds (e.g. Cup & lock, H frame,
Insulating modular scaffolds) shall be followed unless a competent person approves
the variance and provided the variance complies with applicable regulations and
generally accepted scaffold engineering practices.
Proprietary/special scaffold manufacturer’s guidelines for erection and inspection

should be available on share network and with plant maintenance engineer for
reference.
The following safe practices with respect to tube and coupler scaffolds shall be followed:
a) There shall be firm foundation for all scaffoldings. All scaffolding shall be made
of sound material. Scaffolding material shall be inspected and used, only if
found in good condition. Avoid using rusted equipment or equipment whose
strength is not known.
b) Provide adequate sills for scaffolding posts. Metal base plate is used under all
upright or standard scaffoldings. Correct type of couplers shall be used for all
connections.
c) Plumb and level scaffoldings as erection proceeds, so that braces will fit
without forcing. Fasten all braces securely.
d) Where scaffoldings are erected above walkways or work areas, the space
between toe board and railing should be screened.
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e) Whenever work is being done over men who are working on scaffolding,
overhead protection should be provided on the scaffolding.
f) Restrain free-standing scaffolding towers from tipping by guying or other
means.
g) A safe and convenient means of access should be provided to the platform
level. Means of access may be a portable ladder, fixed ladder, ramp or runway
or stairway. The ladder shall be so installed that there supporting member
(pipe) is just below ladder rung. This is to avoid tripping hazard, especially
while using the ladder.
h) During erection, the ladder shall be installed as early as practicable, but not
later than first two horizontal members (Ledgers). This is to facilitate
Scaffolders while erecting the scaffold.
i) Ladder should be provided with tie rods/studs at top and bottom rungs.
j) Do not cantilever or extend putlogs / trusses as side brackets, without
thoroughly considering the loads to be applied.
k) Do not climb cross braces.
l) Do not use ladders or makeshift devices on top of scaffoldings to increase the
height.
The following safe practices with respect to platform planks shall be followed:
a) Use only properly graded and inspected Metallic Plank.

b) Have at least 12” overlap and 6” extension beyond centerline of support or cleat both
ends to prevent sliding.
c) The unsupported length of plank beyond support should not be more than 150 mm
d) Planks shall be non-greasy and free from defects.
e) Access to working platform shall be suitably protected against inadvertent fall by
providing swing members/ swing gate or chains.
f) The working loads permitted on scaffolding platforms should follow the guidelines
given in the table below:
Distribute
Commonly Max. bay
d load on
Max. no. of used widths lengths
Duty Use of platform platforms
platforms using 225 mm
boards Meters
Kg/Sq. M
Inspection Inspection, 76 1 working 3 boards 2.7
and very painting, stone platform
light duty cleaning, light
cleaning and
access.
Light duty Plastering, painting, 150 2 working 4 boards 2.4
stone cleaning, platforms
glazing and painting
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General General building 200 2 working 5 boards or 4 2.1

purpose work including platform + 1 at boards + 1 inside
brickwork, window very light duty
and mullion fixing,
rendering,
plastering.
Heavy duty Block work, 250 2 working plat 5 boards or 5 2.0

brickwork, heavy form + 1 at boards + 1 inside
cladding. very light duty or 4 boards +
1 inside
Masonry or Masonry work, 300 2 working plat 6 to 8 boards 1.8

special duty concrete block form + 1 at
work and very very light duty
heavy cladding.
Reference: Shell Scaffolding Safety procedure
Use and install scaffolding accessories in

accordance with manufacturer’s recommended
WARNING procedure. Do not alter accessories in the field!
Mobile Scaffoldings:
♦ In mobile scaffoldings attach castors with plain stems to the panel or adjustment
screw by pins or other suitable means.
♦ Mobile Scaffolding should be inspected as per Annexure 3-4 in every 3 months
♦ Scaffolding should be checked before use, If observed any problem same should
be corrected .
♦ Do not ride rolling scaffoldings.
♦ Remove all material and equipment from platform before moving scaffolding.
♦ Apply castor brakes at all times when scaffolding is not being moved.
♦ Do not try to move rolling scaffolding without sufficient help. Watch out for holes in
the floor and for overhead obstructions.
♦ Do not use brackets on rolling scaffoldings without first considering the overturning
effect.
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6.3. Scaffolding Usage:
Scaffolds must be used only after these are duly inspected,

certified and tagged ”SCAFFOLD COMPLETE
CAUTION READY FOR USE”
Do not use scaffolding tagged ”SCAFFOLD INCOMPLETE

DO NOT USE”
WARNING
The user shall inspect the scaffoldings every week during

NOTE
their use. The checklist given in Annexure -2 shall be
used for their audit.
a) All employees who use scaffolds shall be trained. The scope of the training shall
include the appropriate safe working practices for the work to be performed and
guidance on assessing hazards and selecting the proper protective measures.
b) Personnel working below and passersby shall be protected from overhead

hazards.
c) Safe access shall be provided for scaffold users. Cross-bracing shall not be
used for access. End frames shall not be used for access unless they were
designed for use as access.
d) Employees who use scaffolds must assess the hazards posed by working on
them and take appropriate precautions to mitigate the hazards.
e) No scaffold shall be loaded beyond the working load for which it is intended.
f) Employees shall use appropriate fall-arrest equipment in accordance with

Engineering Standard on “Safety belts and fall protection system” on scaffolds
not equipped with standard top-rail, mid-rail, toe guard and complete decking.
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6.4. Storage and inspection of materials:
6.4.1 All scaffolding material shall be stored at designated location to protect them from
adverse environment conditions such as corrosion, weather. Storage racks/
Locations/ areas shall be clearly identified. Long term storage of scaffolding
material may be at a single location. From designated storage, the requisite
material should be moved to the location, as transit storage, for immediate use for
erection of scaffolding. The dismantled scaffolding material should not be allowed
to pile up in the plant area. Storage facility of scaffold material shall be properly
constructed for its stability and load bearing capability.
Scaffold material and components shall be inspected

NOTE
before use. They should be inspected before returning to
storage.
6.4.2 Scaffolding material such as tubular, planks, clamps etc. shall be inspected
annually by the user department to ensure they are free from defects. The
visual inspection shall cover 100% scaffold materials. The inspected lot of
material shall be suitably painted with the following colors which will be in
rotation every three years.
FY-2016 - Yellow
FY-2017 - Green
FY-2018 - Orange
FY-2019 - White
Information on inspecting scaffold components and testing scaffolds planking can
be found in the manufacturer’s literature.
6.5. Scaffolding Related Check sheets:
Scaffolds and scaffold material used at site shall be inspected as per the check sheets
attached in Annexure.
Annexure 1 Scaffold Safety Sign Boards

Annexure 2 Scaffolding request
Annexure 3 Scaffolding Inspection Check List
Annexure 4 Certificate of Fitness of Scaffolding
Annexure 5 Weekly Recertification for Fitness of Scaffolding
Annexure 6 Scaffolding Audit Check List
Annexure 7 Scaffold pipes, clamps, planks, toe guards check list.
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7. Management Systems
7.1. Related Procedures
HZL Work at Height Procedure.
7.2. Management of Records
SN Description of the Responsibility Location Min retention

record period
(MONTH)
1 Request for Maintenance/ Maintenance 06

Scaffolding Office/Project
Project
Office
2 Inspection Check Competent Maintenance 06

List Person Office/Project
Office
3 Certificate for Permit Issuing Maintenance 06

Fitness of Department Office/Project
Scaffolding Office
4 Weekly Permit Issuing Maintenance 06

Recertification for Department Office/Project
fitness of Office
Scaffolding
5 Scaffolding Audit Maintenance/ Maintenance 06

Check List Project Office/Project
Office
6 Scaffold pipe , Maintenance/Pr Maintenance 06

Ladder , Clamp , oject Office/Project
Planks ,Base Plate Office
Check List
7.3. Audit Requirements:

Half Yearly auditing of Scaffolds shall be done as part of procedure compliance
by a three member audit team comprising representatives from SHE, plant /
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area and Conformity to the various procedures on use, storage and inspection
of scaffolds and their quality as prescribed in the present document will be
evaluated during these audits by using checklists meeting the HZL group
standards or as per Site Specific Procedure.
7.4. Procedure Renewal Process

The procedure shall be reviewed and revised as necessary and at a minimum,
not later than 3 years from the date of the last revision. SRP committee shall
review the procedure.
7.5. Deviation Process

Deviations from this procedure must be authorized by the Location Head after
consultation with the SRP Subcommittee. Deviations must be documented, and
documentation must include the relevant facts supporting the deviation decision.
Deviation authorization must be renewed periodically and no less frequently
than every 3 years.
Emergency deviations must be authorized by the site manager when, as a

result of an unforeseen event or situation, there is inadequate time to process a
formal deviation. Emergency deviations shall be authorized only where it is not
feasible to comply with a requirement in this standard. Emergency deviations
shall be short in duration, not to exceed the time to perform the task at hand.
Appropriate SHE resources shall be consulted. The deviation must be
documented. The documentation must include the relevant facts supporting the
deviation decision and the interim measures to be put in place to achieve
acceptable levels of SHE protection. A copy of the deviation must be sent to
Central Safety Council.
7.6. Training and communications Requirements

7.6.1 Various personnel connected with the preparation and use of Scaffolds must
undergo safety training programme as per procedure.
7.6.2 All parties concerned in the erection, maintenance and dismantling of

scaffolds shall have a basic training in the relevant code of practice and
safety regulations. SRP subcommittee/Contract SHE committee of HZL shall
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facilitate the training/validation whichever is applicable and ensure that all

relevant employees/the contractors are covered.
7.6.3 The scaffolds supervisor shall be validated and certified by Engineering

Head. The supervisor must undergo standard training module on scaffolds.
7.6.4 All Scaffolders shall be trained and validated by scaffolds supervisor (also
known as competent person).
7.6.5 All scaffolds users must be aware of “Do’s and Don’ts of Safe Usage of
Scaffolds and Ladders”. Refer to Annexure-8 “Do’s and Don’ts of Safe
Usage of Scaffolds & Ladders”.
7.6.6 The contractor is responsible to ensure that his supervisors and Scaffolders
are provided technical and practical training required for the job.
The updated content of this document should be covered

NOTE
in training.
7.7. Contact
The contact for this document is the Corporate SRP subcommittee.
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8. Annexures:
Annexure-1
SCAFFOLD SAFETY SIGN BOARDS :
SCAFFOLDING INCOMPLETE
DO NOT USE
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SCAFFOLDING COMPLETE READY FOR USE
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Annexure -02
REQUEST FOR SCAFFOLDING
I hereby request that the scaffolding may please be erected Light duty/ General
purpose/ Heavy duty/ Masonry or special duty (tick whatever applicable) fit for a
load of --------------------------- kg/ sq. mt. ( KN/sq.m.).
(Location & completion date/time may also be specified)
Request Date: Required Erection Date :
Unit: SBU: _____________
Equipment (Where scaffolding to be erected) ________________
Dimensions Required (In Meter): Length _______Width _____Height_____
Job Completion Date:
Name of Maintenance Engineer Sign of Maintenance Engineer
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Annexure-3
SCAFFOLDING INSPECTION CHECK LIST
Yes/
SN Checks Points No / Remarks
NA
Are the scaffoldings erected as per the load
1. duty requested?
Is every work platform fitted with handrail (top

rail 1050 mm and mid rail at 580 mm high) and
2. a toe board 150 mm secured to the platform
sides?
Are the scaffolding in plumb and level?

3.
Are the Planks/gratings placed in order without
4. undue gaps and anchored?
Are the footing / anchorage for scaffolds sound

and the bay lengths maintained as per the
5.
maximum Intended load?
Are the poles, legs or uprights of scaffolding

are securely braced to prevent swaying /
6.
displacement?
Are the base plates (150 x 150 x 6 mm)

7. provided for scaffolding posts?
Are the base plates are supported by sole

8. plate (Metallic: “300x450x16mm or Wooden:
“300x450x40 ) at unpaved area?
If the scaffolding is erected above walkways or
work areas, are the space between toe boards
9.
and railings screened?
If work is done over men who are working on

10.
scaffolding, is overhead protection provided?
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Has the scaffolding area suitably barricaded

11. during erection / usage / dismantling?
Are free standing scaffolding towers protected

12. from tipping by guying or other means?
Is there a safe and convenient means of

access? If a ladder is used, is it rising at least
13.
1050mm above the platform?
Are relevant status boards (tags) attached to

the scaffolding completed / under erection as
14.
applicable?
Is safe access to equipment or emergency

15. egress restricted by scaffolds?
Are wall scaffolding anchored every 10m of

16. length and 8m of height?
Are landing platforms provided for access

17.
ladders more than 9 meters height?
If two pipes are connected, Are they
18. overlapped at least 600 mm and at least two
clamps are used?
Name of Maintenance Engineer Sign of Maintenance Engineer
(Check list be signed by the person verifying its status)
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Annexure 4
CERTIFICATE OF FITNESS OF SCAFFOLDING
I hereby certify that the scaffolding erected for PTW work permit no. -------------------
and Work @Height Permit No ……………….is ready and fit for use. I further certify
that it is intended for very light duty/ Light duty/ General purpose/ Heavy duty/
Masonry or special duty ( tick whatever applicable) service and should not be
loaded beyond ------------------------- kg/ sq. m. ( KN/sq.m.).
Name and signature of Name and signature of
Maintenance Engineer Scaffolding Supervisor
(Dept……………..) Scaffolding Contractor : M/S
Maintenance Contractor : M/S
Date:
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Annexure 5
WEEKLY RECERTIFICATION FOR FITNESS OF SCAFFOLDING
(APPLICABLE TO LONG DURATION WORK OR ELSE MAY BE SPECIFIED)
Certification Date Scaffolding is Scaffolding Name and Name and

for inspected as is safe for sign of sign of
Annexure -03 use scaffolding maintenance
(any new observation) ( Yes/ No) supervisor engineer
2nd week
3rd week
4th week
5th week
6th week
7th week
8th week
9th week
10th week
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Annexure 6
Scaffolding Audit check list

Date: _______________
SN Checks Points Rating Remarks

1. Has the request for scaffolding been signed by
authorized person?
2. Has the 'certificate of fitness of scaffolding' been

signed by a scaffolding supervisor and
maintenance engineer?
3. Are the scaffoldings erected as per the load duty
requested?
4. Is every work platform fitted with handrail (top rail
1050mm and mid rail at 580 mm high) and a toe
board 150 mm secured to the platform sides?
5. Are the scaffolding in plumb and level?
6. Are the gratings placed in order without undue

gaps and anchored?
7. Are the footing / anchorage for scaffolds sound and

is the bay lengths maintained as per the max.
Intended load?
8. Are the poles, legs or uprights of scaffolding are

securely braced to prevent swaying /
displacement?
9. Are the base plates (150 x 150 x 6 mm) provided

for scaffolding posts?
10. Are the base plates are supported by sole plate
(Metallic : “300x450x16mm or Wooden :
“300x450x40 ) at unpaved area?
11. If the scaffolding is erected above walkways or

work areas, are the space between toe boards and
railings screened?
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12. If work is done over men who are working on

scaffolding, is overhead protection provided?
13. Has the scaffolding area suitably barricaded during

erection / usage / dismantling?
14. Is free standing scaffolding towers protected from

tipping by guying or other means?
15. Is there a safe and convenient means of access? If

a ladder is used, is it rising at least 1050mm above
the platform
16. Are relevant status boards (tags) attached to the

scaffolding completed / under erection as
applicable?
17. Is safe access to equipment or emergency egress
restricted by scaffolds?
18. Are wall scaffolding anchored every 10m of length

and 8m of height?
19. Are landing platforms provided for access ladders

more than 9 meters height?
20. If two pipes are connected, Are they overlapped at

least 600 mm and at least two clamps are used?
Total Marks scored

Overall Rating
Auditor 1: Name: ____________________ Sign: ___________
Date :
26
Annexure 7
Scaffold Pipe, Ladder, Plank/ Jali, Clamps, Base Plate Check list
Material Checklist Observation

Pipes - Rust Free Pipes
- No Bends, Cuts, Holes
- No Sharp edge, pipe end condition
- Pipe thickness minimum 3 mm
- Painted / galvanized pipes
- Any other(Specify)
Ladder - Rail Damaged (cracks, deformation etc.)
- Rust free & Properly Painted Ladder.
- No Cut, Hole or any Physical damage.
- Equal spacing between rungs (max 30 cm).
- Ladder width greater than = 30 cm .
- No Bent, Broken, loose Rungs ,No Sharp Edge
- No Oil, Grease and other slippery items
- Bottom non-skid pad damaged/missing
- Top and bottom rung tie rod provided
Plank/Jali - Gap between two plank Max should be 25 mm
- Plank all 4 hooks not damaged.
- No Cut or any other Physical damage.
- Not depressed beyond 15 mm.
- Rust free and properly painted.
- Flat Thickness 3mm internal and 5mm outer
Clamps - Rust free and properly painted.
- No cut/cracks or physical damage.
- No lubrication.
- No Eyebolts bent.
- Thread condition/Nut condition.
- No welding / local repair
Base Plate & - Rust free and properly painted.
Sole Plate - No bend, No Cut, Hole or physical damage.
- Flat Bottom portion.
Inspected By:
Name & Sign : Date :
27
Annexure 8
Do’s for scaffold users:
Use only certified scaffolding, tagged with ―Scaffolding Complete, Ready for Use
Maintain three-point-contact while climbing up or down the ladder.
Use rope or container or other suitable means for carrying material from or to ground.
Maintain good housekeeping, especially at elevated working platform and near the
access.
Do take special precautions while working in vicinity of mobile cranes or electrical
overhead lines.
Wear full body safety harness with double lanyard/ personal fall arrest system or other
equally effective means while ascending or descending the ladder or scaffolding
working platform is not fully guarded.
Do check for emergency approach/ evacuation, especially adequacy means of egress.
Use safe material handling ways while shifting the material.
Do report ―At-risk conditions‖ e.g. missing ladder, incomplete decking, improper
guarding, no landing platform, loosely clamped ladder, etc. to your supervisor.
Do check weekly certification of scaffold at random
Don’ts for scaffold users
Do not use any part of operational line or pressurized piping as a support, or tie point for
scaffolds or staging. Do not permit mixing of scaffold types in any one structure (e.g.,
steel/aluminium couplers, wooden boards/metal grid boards).
During the possibility of a thunderstorm, no work shall be executed at a height where a
person can be exposed to lightning.
Never keep loose tools, materials etc at height in a way it may roll off and fall from height.
Do not use cross-bracing or end-frame (unless specially designed) for access.
Avoid overloading and impact loading
Never alter or modify or dismantle any part of the scaffold without permission from
scaffolding supervisor or concerned Maintenance /Project Engineer.
Do not throw tools or scaffolding materials from height.
Do not use ―Incomplete Scaffold.
28

Hindustan Zinc Limited Chanderiya Lead Zinc Smelter Scaffold Safety Procedure

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Hindustan Zinc Limited Chanderiya Lead Zinc Smelter Scaffold Safety Procedure

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Hindustan Zinc Limited

Chanderiya Lead Zinc Smelter

1.1. Intent and Purpose:

2. Scope and field of application:

Scaffold safety Standard,

IS: 3521 – 1999 Industrial safety belts and harnesses

Examples include fabricated-frame scaffold, system scaffold, tube-and-coupler

6.1.1 Categories and classification:

Most scaffolds fall into one of the four primary categories:

Scaffolds are classified according to their intended use as:

6.1.2 Specifications of scaffolds:

Applicable to all scaffolds:

Applicable to Tube-and-coupler scaffold

9. Minimum height of first horizontal member (Ledger) of scaffolds from the

12. Minimum overlap of vertical members (standards) and/ or horizontal members

Applicable to Mobile scaffolds:

6.1.3 Control and handover procedure:

Scaffolding control and hand-over procedures shall be as described below:

a) The requirement of scaffolding for working at heights will be as stated in the

c) The scaffolding contractor/Maintenance Contractor shall erect the scaffoldings

d) Appoint a scaffolding supervisor (competent person).

g) Adhere to the written hand-over procedure and maintain good communication

l) In the event of any doubt concerning the integrity of a particular scaffold,

Scaffolding Process Flow chart

Scaffold Request generation by

Scaffolding completed as per

Arrange inspection of scaffolding by Certified Scaffolding Inspector as per Annexure 03 and do

Put Green Tag on Scaffolding and surrender Scaffolding Erection Permit

Weekly Audit of Scaffolding to be done as per Annexure -05 and Signed on

6.2. Erection, dismantling, movement and modification

Timber scaffolds shall not be used except under special

No erection, dismantling, movement and modification

An assessment of hazards shall be made before erecting, dismantling, moving, or

Standard scaffold planks shall not be used for purposes other

Proprietary/special scaffold manufacturer’s guidelines for erection and inspection

a) Use only properly graded and inspected Metallic Plank.

General General building 200 2 working 5 boards or 4 2.1

Heavy duty Block work, 250 2 working plat 5 boards or 5 2.0

Masonry or Masonry work, 300 2 working plat 6 to 8 boards 1.8

Use and install scaffolding accessories in

6.3. Scaffolding Usage:

Scaffolds must be used only after these are duly inspected,

Do not use scaffolding tagged ”SCAFFOLD INCOMPLETE

The user shall inspect the scaffoldings every week during

b) Personnel working below and passersby shall be protected from overhead

f) Employees shall use appropriate fall-arrest equipment in accordance with

6.4. Storage and inspection of materials:

Scaffold material and components shall be inspected

Annexure 1 Scaffold Safety Sign Boards

SN Description of the Responsibility Location Min retention

1 Request for Maintenance/ Maintenance 06

2 Inspection Check Competent Maintenance 06

3 Certificate for Permit Issuing Maintenance 06

4 Weekly Permit Issuing Maintenance 06

5 Scaffolding Audit Maintenance/ Maintenance 06

6 Scaffold pipe , Maintenance/Pr Maintenance 06

7.3. Audit Requirements:

7.4. Procedure Renewal Process

7.5. Deviation Process

Emergency deviations must be authorized by the site manager when, as a

7.6. Training and communications Requirements

7.6.2 All parties concerned in the erection, maintenance and dismantling of

facilitate the training/validation whichever is applicable and ensure that all

Dimensions Required (In Meter): Length _____Width _Height___

Auditor 1: Name: __________ Sign: _