CRAI PPE Manual

CR Asia Group
Manual
Personal Protective Equipment (PPE)
Revision Record
Issue Revision Page Prepared Approved DAR

Date Description of Revision
No. No. Edition By by No.
Esablished /Revised; Reviewed / Communicate; Group Reviewed; Accepted / Approved;
(Issac John)
Safety Engineer CRAI
Document: Revision Number: 00

Issue Date: Issue Number: 00 Page : 1 of 20
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1. Objective
This Personal Protective Equipment Manual will help the employees do the following:
 Understand the types of PPE.
 Select appropriate PPE for a variety of circumstances.
 Understand what kind of training is needed in the proper use and care of PPE.
2. Scope
Employee who currently utilize PPE or who may encounter hazards to the eyes, face, head, feet, hands, or
who conduct work involving electrical or fall hazards, as identified during the Hazard Assessment of the
workplace, are subject to these PPE Guidelines. PPE will be selected and used to protect employees from the
hazards and potential hazards that they are likely to encounter. PPE should not be used as a substitute for
engineering, work practices, and/or administrative controls to protect employees from workplace hazards.
PPE should be used in conjunction with permanent protective measures, such as engineered guards,
substitution of less hazardous chemicals, and prudent work practices.
3. Reference
The information in this manual is general in nature and does not address all workplace hazards or PPE
requirements. The information, methods and procedures in this manual are based on the OSHA
requirements for PPE as set forth in the Code of Federal Regulations (CFR) at
29 CFR 1910.132 (General requirements);
29 CFR 1910.133 (Eye and face protection);
29 CFR 1910.135 (Head protection);
29 CFR 1910.136 (Foot protection);
29 CFR 1926.95 (Criteria 5 for personal protective equipment);
29 CFR 1926.101 (Hearing protection);
29 CFR 1915.157 (Hand and body protection)
Different Indian Standards in regard with the equipment (mentioned in the contents).
4. Roles & Responsibilities
4.1 Operation Manager / Division Manager and Project Managers
These appointment holders must have a legal responsibility to ensure that:

 The appropriate Personal Protective Equipment as prescribed in the regulations is provided;
 PPE provided is maintained in good condition;
 PPE provided is used as prescribed;
 Workers are provided information, instruction and supervision on the use and care of required PPE;
 they comply with the regulations or standards limiting the exposure of a worker to biological, chemical, or
physical agents as prescribed in the regulation; and
 Every reasonable precaution is taken to protect the health and safety of the worker.
4.2 Engineers / Safety Officers/ Supervisors
These appointment holders have a legal responsibility to ensure that:

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 Workers use and wear properly, the appropriate PPE (including protective clothing) that the employer
requires to be used or worn;
 Workers are trained in the use and care of required PPE before they wear or use the protective
equipment;
 Records of this training are maintained and kept in an accessible location;
 Workers are informed of the existence of any potential or actual danger to the health and safety of
which the supervisor is aware;
 Every reasonable precaution is taken to protect the health and safety of the worker.
4.3 Workers
Workers should ensure that:

 They use or wear properly the PPE that the employer requires to be used or worn;
 They inspect PPE regularly before each use;
 Absences or defects in any PPE of which the worker is aware and may endanger themselves or
another worker is reported to their supervisor or employer immediately;
 They do not use PPE in a manner that may endanger themselves or others
5. Training
Prior to conducting work or being in a PPE prescribed area requiring the use of PPE, workers/students shall
be trained in the following:
When PPE is necessary;
What type is necessary;
How it is to be worn;
What its limitations are;
Proper care, maintenance, life expectancy and disposal
Safety Officer/Engineer must provide training to ensure the worker/student is able to demonstrate, upon
completion of the training
6. Hierarchy of Control & Personal Protective Equipment
The standard approach to dealing with potential hazards must include a risk assessment to determine the
requirement for PPE use. There are five basic ways to control hazards, where elimination is always the first
control to consider. After that, proceed down the hierarchy until the control of last resort being PPE.
 Elimination (remove the hazard from the work site)
 Substitution (use a less harmful chemical)
 Engineering (isolate equipment/set guards)
 Administration (provide training/maintenance)
 Personal Protective Equipment (provide gloves/goggles)
The use of PPE does not prevent accidents or eliminate hazards. Make every effort to control all hazards at
the source. Training is also important. PPE cannot achieve its full-protection potential without worker
knowledge and cooperation.
Several controls may have to be put in place. Certain hazards may require multiple PPE solutions. Wearing
PPE should not add to the hazard or create a new hazard. For instance, proper glove selection can prevent
skin damage, but gloves worn while working with moving equipment can create an entanglement hazard.

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Using different types of protection at the same time i.e. hard hat, earmuffs and goggles, should not increase
the risk to the worker.
PPE design criteria cannot cover all eventualities. Do not use PPE when its usage creates hazards greater than
those for which it is designed. Take uncertainties into account when evaluating potential hazards.
7. Selection of PPE
Once the need for PPE has been established, the next task is to select the proper type. Two criteria need to
be determined:
Degree of Protection
Appropriate Design
7.1 Guidelines for selection:
Match PPE to Hazard

Choose the right PPE to match the hazard. In some jobs, workers continually perform the same task. In
other jobs workers may be face different hazards. For instance, a welder requires protection against
welding gases (respirator), harmful light rays (welder’s goggles), and molten metal and flying chips
(gloves, welding hood, welding helmet).
Involve Workers/Users
To ensure that the fit, comfort, and acceptability of the PPE, involve workers/users in valuations of PPE.
Allow for personal preferences and flexibility with choice of PPE, as long as it meets the required
legislation and standards.
Check the Fit
It is important to fit each user with PPE individually. Certain fitting programs require qualified personnel.
Some types of equipment, like respirators, require annual fit testing to ensure they fit the face of the
individual worker. Show workers how to wear and maintain PPE at the time of fitting.
Training
Workers and their supervisors need training in when, where, why, and how to use the equipment to
achieve the necessary level of protection. All workers need training, whether exposed on a regular or
occasional basis, for example, in emergencies or with temporary work in dangerous areas.
Maintenance
Wearing poorly maintained or malfunctioning PPE can be as dangerous as not wearing any protection.
Without proper maintenance, the effectiveness of PPE cannot be assured. The most important part of
maintenance is the need for continuing inspection. Discard PPE not performing to manufacturers’
specifications. Set up procedures to enable workers to obtain replacement parts for damaged PPE and
keep it clean.
Maintenance includes: inspection, care, cleaning, repair, and storage.
Review
Monitor the effectiveness of the PPE program by inspecting the equipment and auditing procedures.
Evaluate whether the equipment is used regularly and appropriately. Review the program at least
annually. Review critical areas more frequently. Review and compare production and safety performance
records.
8. Eye & Face protection
Employees can be exposed to a large number of hazards that pose danger to their eyes and face. OSHA
requires employers to ensure that employees have appropriate eye or face protection if they are exposed to
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eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical
gases or vapors, potentially infected material or potentially harmful light radiation.
Many occupational eye injuries occur because employees are not wearing any eye protection while others
result from wearing improper or poorly fitting eye protection. Employers must be sure that their employees
wear appropriate eye and face protection and that the selected form of protection is appropriate to the work
being performed and properly fits each employee exposed to the hazard.
8.1 Over Glass Safety Goggles/ Safety Clip-ons
Everyday use of prescription corrective lenses will not provide adequate protection against most
occupational eye and face hazards, so employers must make sure that employees with corrective lenses
either wear eye protection that incorporates the prescription into the design or wear additional eye
protection over their prescription lenses. It is important to ensure that the protective eyewear does not
disturb the proper positioning of the prescription lenses so that the employee’s vision will not be
inhibited or limited. Also, employees who wear contact lenses must wear eye or face PPE when working
in hazardous conditions.
8.2 Types of Eye & Face Protection
Selecting the most suitable eye and face protection for employees should take into consideration the
following elements:
 Ability to protect against specific workplace hazards.
 Should fit properly and be reasonably comfortable to wear.
 Should provide unrestricted vision and movement.
 Should be durable and cleanable.
 Should allow unrestricted functioning of any other required PPE.
The eye and face protection selected for employee use must clearly identify the manufacturer. Any new
eye and face protective devices must comply with ANSI Z87.1-1989 or be at least as effective as this
standard requires. Any equipment purchased before this requirement took effect on July 5, 1994, must
comply with the earlier ANSI Standard (ANSI Z87.1-1968) or be shown to be equally effective.
An employer may choose to provide one pair of protective eyewear for each position rather than
individual eyewear for each employee. If this is done, the employer must make sure that employees
disinfect shared protective eyewear after each use. Protective eyewear with corrective lenses may only
be used by the employee for whom the corrective prescription was issued and may not be shared among
employees.
Some of the most common types of eye and face protection include the following: n Safety spectacles.
These protective eyeglasses have safety frames constructed of metal or plastic and impact-resistant
lenses. Side shields are available on some models.
 Goggles. These are tight-fitting eye protection that completely cover the eyes, eye sockets and the
facial area immediately surrounding the eyes and provide protection from impact, dust and
splashes. Some goggles will fit over corrective lenses.
 Welding shields. Constructed of vulcanized fiber or fiberglass and fitted with a filtered lens, welding
shields protect eyes from burns caused by infrared or intense radiant light; they also protect both
the eyes and face from flying sparks, metal spatter and slag chips produced during welding,
brazing, soldering and 12 cutting operations. OSHA requires filter lenses to have a shade number
appropriate to protect against the specific hazards of the work being performed in order to
protect against harmful light radiation.

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 Laser safety goggles. These specialty goggles protect against intense concentrations of light
produced by lasers. The type of laser safety goggles an employer chooses will depend upon the
equipment and operating conditions in the workplace.
 Face shields. These transparent sheets of plastic extend from the eyebrows to below the chin and
across the entire width of the employee’s head. Some are polarized for glare protection. Face
shields protect against nuisance dusts and potential splashes or sprays of hazardous liquids but
will not provide adequate protection against impact hazards. Face shields used in combination
with goggles or safety spectacles will provide additional protection against impact hazards. Each
type of protective eyewear is designed to protect against specific hazards. Employers can identify
the specific workplace hazards that threaten employees’ eyes and faces by completing a hazard
assessment
Normally used Brands by CR includes MSA, KARAM, 3M, FRONTIER, HONEYWELL, UNICARE etc. which
are compliance to either IS 5983:2020 or EN166 ANSI-Z87.1
9. Head Protection
Helmet is one of the most important items of personal protective equipment used by workers for protection
against head injuries which may be caused by falling objects in many industries, for example, mining,
tunnelling, quarrying, ship building, construction projects and similar occupations. Head injuries caused by
falling objects are usually serious and sometimes fatal.
Engineers must ensure that their workers wear head protection if any of the following apply:
 Objects might fall from above and strike them on the head;
 They might bump their heads against fixed objects, such as exposed pipes or beams; or
 There is a possibility of accidental head contact with electrical hazards.
Whenever there is a danger of objects falling from above, such as working below others who are using tools
or working under a conveyor belt, head protection must be worn. Hard hats must be worn with the bill
forward to protect employees properly. In general, protective helmets or hard hats should do the following:
 Resist penetration by objects.
 Absorb the shock of a blow.
 Be water-resistant and slow burning.
 Have clear instructions explaining proper adjustment and replacement of the suspension and
headband.
The hard hats should have undergone test on the following areas prior to usage:
 Shock absorption resistance
 Penetration resistance
 Flammability resistance
 Electrical resistance
 Water absorption
 Heat Resistance
Hard hats must have a hard outer shell and a shock-absorbing lining that incorporates a headband and straps
that suspend the shell from 1 to 1 1/4 inches (2.54 cm to 3.18 cm) away from the head. This type of design
provides shock absorption during an impact and ventilation during normal wear. Protective headgear must
meet ANSI Standard Z89.1-1986 (Protective Headgear for Industrial Workers) or should follow IS 2925 (Indian
Standard for Hard hat).
Normally used Brands by CR includes MSA, KARAM, 3M, UDYOGI & RATCHET etc. which are compliance to IS:
2925

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10. Hand & Arm protection
About one-third of the injuries that occur involve hand and arms. Such injuries occur when the workman
has to handle materials with sharp ends, hot metals, chemicals, corrosive substances, electrical works, etc.
Because of apparent vulnerability of the fingers, hands and arms, the use of PPE for protection of hand and
arm becomes necessary for workers. The portion of hand and arm exposed to the hazard is to be fully
covered with suitable material that provides adequate protection against the hazard.
It should be remembered that gloves should not be used while working on moving machinery such as drills,
saws, grinders or other rotating and moving equipment that might catch the glove and pull it along with the
worker’s hand into the machinery. In situations where gloves are used to protect workers’ hands from
chemical solutions, the gloves should be long enough to extend well above the wrist, but so designed that
there is no flaring cuff which might trap any splashes and introduce the liquid into the glove. It should fit
tightly around the forearm. It is advisable for the sleeves to be worn outside the glove cuff. Electric line
repairers working around energised high voltage should use specially made and tested rubber gloves.
The following are examples of some factors that may influence the selection of protective gloves for a
workplace.
 Type of chemicals handled.
 Nature of contact (total immersion, splash, etc.).
 Duration of contact.
 Area requiring protection (hand only, forearm, arm).
 Grip requirements (dry, wet, oily).
 Thermal protection.
 Size and comfort.
 Abrasion/resistance requirements.
Gloves made from a wide variety of materials are designed for many types of workplace hazards. In
general, gloves fall into four groups:
 Gloves made of leather, canvas or metal mesh;
 Fabric and coated fabric gloves;
 Chemical- and liquid-resistant gloves;
 Insulating rubber gloves (29 CFR 1910.137).
Rubber gloves (IS: 4770-1991) for electrical purposes offer protection against electric shock while working
on energized conductors and equipment. However, it does not imply that rubber gloves shall be the only
means of protection for working on live circuits or components. The specifications deal with four types of
gloves suitable for maximum working potential of 650, 1100, 3300 and 4000 Vrms.
Gloves for protection against chemicals are made of materials impervious to liquids for protection against
irritating corrosive substances. No one type is universally suitable against all possible hazards. The choice
depends on the particular acid, solvent, caustic, oil, chemical, etc. involved. No Indian standard is available
for chemical safety gloves. The level of protection provided by a chemical resistant glove depends on several
conditions, such as chemical concentration, temperature and duration of use. Gloves for protection against
hot work are meant to follow guidelines as per IS: 6994 (Part 1) – 1973.
Protective gloves should be inspected before each use to ensure that they are not torn, punctured or made
ineffective in any way. A visual inspection will help detect cuts or tears but a more thorough inspection by
filling the gloves with water and tightly rolling the cuff towards the fingers will help reveal any pinhole leaks.
Gloves that are discoloured or stiff may also indicate deficiencies caused by excessive use or degradation
from chemical exposure. Any gloves with impaired protective ability should be discarded and replaced. Reuse
of chemical-resistant gloves should be evaluated carefully, taking into consideration the absorptive qualities
of the gloves. A decision to reuse chemically-exposed gloves should take into consideration the toxicity of the
chemicals involved and factors such as duration of exposure, storage and temperature.
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Normally used Brands by CR includes Tiger Brand: Cotton Dotted Hand Gloves & Canadian: Leather hand
gloves. which are compliance to IS: 6994
11. Ear Protection
High noise levels are associated with a number of industrial operations and machines. Excessive exposure to high
levels of noise can cause irreparable damage to hearing, in addition to some physiological and psychological
harm. Occupational hearing loss is a notifiable disease under the Factories Act. In order to protect the hearing
capacity of persons working in industries, the exposure to noise should be kept well within the specified
permissible limits. Wherever the noise exceeds the permissible values, control measures should be adopted to
reduce the exposures. Engineering control measures, such as institution of enclosures, process change and use of
personal protective equipment for ears are employed as noise control measures.
Ear protectors fall into three main groups:
 Plug or insert type,
 Cup or muff type, and
 Helmet type, which completely surrounds the head in which the attenuation of sound is achieved
through the acoustical properties of the helmet.
The ear-plugs, if properly fitted, can attenuate noise by 25-30 dB in the high frequencies, which are considered to
be the most harmful. Earmuffs of better quality may reduce noise by an additional 10-15 dB. Combination of ear-
plugs and ear-muffs may reduce noise by an additional 3-5 dB. In no case, the total attenuation will be greater
than 50 dB, because at this point bone conduction becomes significant.
Regular cleaning of ear protectors is important for the sake of proper hygiene. Protectors that become
contaminated or coated with hardened wax may cause discomfort and may lead to infection of middle ear.
Normally used Brands by CR includes 3M,MSA,HONEYWELL,KARAM & VENUS which are compliance to IS:
9167
12. Body Protection
Certain jobs require protection for the whole body, like in the case of exposure to fire, extreme heat, molten
metal, corrosive chemicals, working on refineries, cold temperature, body impact, cuts from materials which
are handled. Other specialised hazards are often part of what is known as ‘job exposure’ (e.g. nuclear
radiation exposure). Protection to body against such exposures can be provided by wearing aprons, overalls,
jackets, complete head-to-toe protective suits, etc. Selection of type of body PPE depends on the nature of
hazard, severity of hazard and nature of activities of concerned user.
For protection against flame or small sparks, one can use ordinary clothing made flame-proof by application
of suitable flame-proofing compounds. Durable, flame-retardant work clothes (NPFA 2112) are available.
Such clothing should be distinctively marked so that untreated garments are not used by mistake by those
need fire-retardant clothing.
Clothing made of impervious materials should be used by workers for protection against dust, moisture (e.g.
Tritium exposure in heavy water nuclear reactors) and corrosive liquids. Materials used for this type of
protection include natural rubber, synthetic rubber, neoprene, vinyl, polypropylene, polyethylene films and
fabrics coated with them. Such impervious clothing (Tyvek Suits) can be used to make different types of body
wears, ranging from aprons and bibs of plastic sheet, to garments which completely enclose the body from
head to foot and contain their own air supply. For the complete enclosure of the body in protective clothing
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made of impervious material, the hose of the supplied air apparatus should be connected to the face-piece
as well as to the suit to provide ventilation.
Normally used Brands by CR includes TYVEK Dupoint & ARVIND which are compliance to EN: 13982-1,
NPFA-2112
13. Respiratory Protection
Respiratory PPE are required by workers in work areas where there is lack of sufficient oxygen or where high
levels of atmospheric contaminants are likely to be present. The contaminants may range from the relatively
harmless substances to toxic dusts, fumes, smoke, mists, vapour and gases. This type of PPE shall be used in
the following situations:
(i) Non-emergency Situations:
When workers are exposed to an atmosphere which does not have a rapid, dangerous effect upon life or
health but will produce chronic illness, pronounced discomfort or permanent physical damage or even death
after prolonged or repeated exposures. Such situations generally involve normal routine operations.
(ii) Emergency Situations:
At times workers are exposed to an atmosphere with high concentrations of contaminant which have a rapid,
harmful effect on life or health even after comparatively short periods. Under such situations, respiratory
PPE should provide complete respiratory protection to the worker with provision for safeguarding the wearer
against even a momentary failure of PPE during exposure to the dangerous atmosphere.
13.1 Selection of Respiratory PPE
A wide variety of respiratory PPE are available from suppliers for persons working in different types of work
situations. The following information is required for deciding on the type of respiratory PPE required:
 the name of contaminant to be guarded against; its chemical, physical
and toxicological properties,
 type of work situation, viz. non-emergency or emergency, and
 the period of time for which respiratory PPE is required to be used.
After considering the above information, refer to below figures for selecting the type or types of respiratory
PPE that would protect the worker. Besides the above selection procedure, the following general principles
must be taken into account:
 Chemical cartridge respirators are suitable only in atmospheres that are not immediately dangerous
to life and that contain a percentage of contaminants not exceeding 0.1 per cent by volume. These
respirators should not be used for following types of contaminants:
 that are extremely poisonous in very small concentrations (e.g. hydrogen cyanide).
 that are not effectively absorbed chemically (e.g. carbon monoxide).
 that are not easily identified by odour (e.g. methyl chloride, hydrogen sulphide).
 that are irritating to eyes (e.g. sulphur dioxide).

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 Canister-type gas masks should be limited to use in atmospheres that are not deficient in oxygen or
where the toxic contaminant does not exceed 2 per cent in concentration (3 per cent for ammonia)
by volume
Classification of Respiratory Protective Devices
Environment Classification for Selection of Respiratory Protection Devices

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13.2 Care of Respiratory PPE
The following considerations should be kept in mind for maintaining the quality of respiratory PPE:
 Where practicable, the respirators should be assigned to individual workers for their exclusive
use.
 It is advantageous to assign two respirators to each individual user. They last more than twice as
long, and helps in carrying out proper servicing of respirators as the second respirator is used
while the first is being serviced.
 Respirators must be cleaned regularly and disinfected.
 Respirators should be stored in a convenient, clean and sanitary location.
 Respirators used routinely should be inspected during cleaning. The deteriorated parts, if any,
should be replaced. Respirators for emergency use, such as self-contained type (e.g. SCBA), are
to be thoroughly inspected at least once a month and after each use.
 Respirators should not be thrown into tool boxes or left on work benches where they may get
exposed to dust or damaged by oil or other harmful materials.
 Respirator should never be hung by the elastic headband or kept in a position, as to stretch the
face-piece.
 Before storing, respirator should be carefully wiped with a damp cloth and dried. It should be
stored without making sharp folds or creases on it. It should be sealed in clean, plastic bags.
 Users should wipe off oil, grease and other harmful substances from head-bands and other
parts of the respirator as soon as they get dirty. Solvents should not be used to clean plastic or
rubber parts.
 Supervisors should be made responsible for daily inspection of respiratory PPE, particularly of
functional parts, such as exhalation valves and filter elements. They should see that the edges
of the valves are not curled and that valve seats are smooth and clean. Inhalation and
exhalation valves should be replaced periodically.
 In addition to daily check, trained persons should inspect the respirators. During weekly
inspection, rubber parts should be stretched slightly for detection of fine cracks. The rubber
should be worked occasionally to prevent setting (one of the causes of cracking), and the
headband should be checked to ensure that the wearer has not stretched it in an attempt to
secure a snug fit.
Normally used Brands by CR includes 3M, Venus & MSA which are compliance to IS: 8523-1977 , IS: 8522-
1977 , IS: 9473-1980 , IS:10245 (Part 3)-1982 , IS: 10245 (Part 2)- 1982 , IS:10245 (Part 40)
14. Foot Protection Equipment
Protection to foot and leg is required while handling material or corrosive and chemical liquids. Commonly
used foot and leg PPE are safety shoes, foot guards, kneepads, leggings and leg guards.
The common foot protection employed in industry is the metal toe-box-safety shoe. This type of shoe is
required when handling heavy materials, rolling objects like barrels, heavy pipes, rolls, truck wheels, to

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protect against kicking sharp sheet metal. In occupations where there is likelihood of heavier objects falling
and striking the toe, then foot guards in addition to safety shoes should be worn. The foot guards are flanged,
heavy-gauge metal and corrugated sheet metal covers that protect the foot from toe to ankle. With the
flanges resting on a firm floor, the foot guard should resist an impact of at least 45 m.kg. without damaging
the shoes underneath or injuring the feet. Metal toe-boxes may also be used for shoes which provide
additional protection against different hazards, for example, conductive-spark resistant shoes, moulder
shoes, non-conductive shoes. Depending on the type of safety shoe, protection against additional hazards
like building of static electricity on person (conductive shoes), resistant against sparks (non-sparking shoes
made without metallic parts), and electric insulation from ground (non-conducting shoes) is provided to
workers. For work under wet conditions, rubber boots/ shoes fitted with steel toe-box provide protection
against impact.
PVC full gums boots with stockinet lining inside and conforming to IS:12254-1988 can be used both for
chemical and electrical purposes,
14.1 Care for Foot Protection equipment
 Leather shoes should be kept as dry as possible. If they get wet, they should be dried slowly.
 User of leather shoes should wash the feet and change socks daily as perspiration harms the leather
and causes the lining of shoes to wear out and become rough.
 Shoes should be kept in good repair, as worn-out soles and rundown heels are dangerous.
 Conductive sole shoes, designed to prevent the accumulation of body static charges, as well as anti-
spark and shock resistant, require special attention. Only repairmen thoroughly familiar with their
construction and trained in approved methods of repairs should attempt this work. The advice of the
manufacturer should be sought.
 Shoes should be cleaned frequently.
 For certain operations, when the workers on different shifts or jobs are required to wear same pair of
rubber boots, it is necessary to disinfect boots after each shift or job.
 The following washing procedure is recommended for rubber boots:
o Inside and outside of rubber boot should be washed with a hose under water pressure.
o Boots should be dipped into a tub containing a solution of 1 part sodium hypochlorite
and 19 parts water.
o The boots should be rinsed with hose under water pressure and dried.
Steel/Composite toe shoes & leather gum boots are used by CR which are compliance to IS 15298-part-3)
15. Full Body Harness
Safety belts and harness are required to be used by workers who have to work at heights, where a fall may
result in serious injury or death. These can be of following types:
 Body Belt:
 To limit movement and positioning
 To restrict the worker to a safe area

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 To help prevent a fall
This is used where freedom of movement is most important and where only limited fall hazards exist. This
is not recommended where vertical free-fall hazards exist.
 Body Harness:
This is used when the worker must move at dangerous heights. In a fall, the harness distributes impact
force over a wider body area than does a belt, reducing the possibility of injury to the wearer.
 Suspension Belt:
This is used at those work situations where it is not possible to work from a fixed surface and the
worker must be totally supported by a suspension harness, as in the case of stack maintenance, tree
trimming, shipboard painting, etc.
It is preferable if belt and harness are made of webbing rather than leather. Webbing has more
strength and stretch; hence it has three to four times greater resistance to impact loading than leather
of same size. Furthermore, the tongue of buckle on leather belt has comparatively less strength due to
cut and pull through holes in the strap, while webbing belts use buckles which avoid loss of strength at
Buckle holes. Also, the leather belt requires special care and treatment to retain its strength, while the
webbing does not. Webbing could be made of cotton or synthetic material such as nylon or dacron
which have superior strength, and resistance to mildew and moisture. For work areas using chemicals
or oils, it is preferable if webbing is coated or impregnated with plastic or neoprene rubber materials.
The weave of webbing should be of herringbone type instead of square (basket) weave. The former
gives approximately twice the strength than basket weave.
Lifelines of safety belts and harness are usually nylon ropes of 12mm diameter or manila ropes of
19mm diameter. Nylon is more resistant to wear or abrasion than manila and is more resistant to some
chemicals. The lifeline should be spliced into snaps and D-rings instead of being knotted. Splicing will
retain approximately 90 per cent of the rated strength of the rope, while knots reduce the strength
considerably, depending upon the type of knot or hitch used and the moisture content of the rope.
The anchorage for lifelines should be selected to permit as little slack as possible, thereby stopping a
worker with minimum of free fall. Special notice must be taken of nearness of any beam or other
obstruction which the workman might strike in case of a fall. The waist-belt should always be inserted
through the D-rings or other devices for attaching the belt to the lifeline. It should never be riveted or
fastened in such a way that the D-rings or lifeline get separated from the belt due to failure of rivets.
15.1 Care of Safety Belts and Harness
Each wearer of safety belt/harness should inspect this PPE daily before use. In case of fabric belts, if the
considerable portion of outer fibres is noticed to be cut or worn, the belt should be rejected. Leather belts
should especially be observed for cuts or deep scratches on the strap. Any deep cut of considerable length,
in a direction across the width of the belt, calls for discarding of the belt. Within 30 to 90 days each belt
should be thoroughly examined by a trained inspector. Belt hardware should be checked and the worn
parts replaced. Each belt rivet should be examined to be certain that it is secure.
Safety belts in service should not be tested, as it may damage the belt, making it unsafe. Therefore, only
sample belts or worn or doubtful belts should be tested for destruction to determine their safety. Belts

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subject to the maximum impact in an accidental fall should not be reused because the fittings might have
been over stressed and weakened. The safety belt should be securely buckled and worn tight enough to
prevent any possibility of the worker slipping out of it.Cotton or linen webbing belts should be washed in
soapy water, rinsed and dried by moderate heat. They are not damaged by temperature up to 1000C.
Synthetic fibre belts should not be exposed to excessive heat as it might soften or melt the fibres or the
chemical, subsequently affecting the composition of the fibre.
More care is to be taken of leather safety belts. Dirt adhering to this type of belt should be brushed off
carefully so as not to scratch the leather. Leather belts should not be exposed to excessive heat, such as
from a radiator, because a temperature as low as 65°C may permanently damage them. A leather belt
which has been unused and not oiled for a year or two is much weaker than one which has been regularly
used and adequately oiled over the same period, even when the unused belt will look newer and stronger.
Leather belt should be oiled with neatsfoot, castor, soya bean or compound oil. Mineral oil should never be
used for leather safety belts.
The performance test should be carried on an articulated anthropometric dummy having a mass of 100 ± 5
kg and an overall height of 1.6 to 1.8 m with waist not more than 100 cm in circumference.
Normally used Brands by CR includes KARAM,UDYOGI etc. which are compliance to IS 3521

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Annexure – I
MATERIALS USED FOR FOOT AND LEG PROTECTION EQUIPMENT AGAINST DIFFERENT
TYPES OF HAZARDS
Sl. No. Material Protection Against Hazard
1 Asbestos Sparks, hot materials and heat.
2 Chrome leather Sparks, hot materials, hot liquids, flying particles

and cuts and abrasions.
3 Flame-proofed duck Sparks, hot materials, heat, flying particles and

machinery.
4 Plastic Hot liquids, moisture, acids and alkalis.
5 Rubber Materials causing dermatitis, hot liquids, moisture,

acids, alkalis and electric shock.
6 Fibre metals Sparks, flying objects, flying particles, cuts, and

abrasions and machinery.
7 Chemical resistant Acids and alkalis.
8 Reflective fabric Hot liquids.

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Annexure – II
TYPES OF SAFETY SHOES TO BE USED FOR DIFFERENT TYPES OF HAZARDS
Sl. No. Type of Safety Protection Against Hazard

Shoes
1. Steel toe caps Falling objects.
2. Non-skid shoes Moisture.
3. Wooden soles Hot materials, heat, hot liquids, moisture, acids and
alkalis, slips and falls and cuts and abrasions.
4. Chrome leather Sparks, hot materials, heat and hot liquids.
5. Rubber Hot liquids, moisture, acids and alkalis, electric shock

and materials causing dermatitis.
6. Conductive rubber Explosive.

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Annexure – III
MATERIALS USED FOR BODY PROTECTION EQUIPMENT AGAINST DIFFERENT TYPES OF
HAZARDS
Sl. No. Material Protection Against Hazard
1. Asbestos Sparks, hot materials and heat.
2. Chrome leather Sparks, hot materials, hot liquids, flying particles, cuts and
abrasions.
3. Plastic Hot liquids, moisture, acids and alkalis, electric shock,
materials causing dermatitis and machinery.
4. Rubber Hot liquids, moisture, acids and alkalis, electric shock,

materials causing dermatitis, and machinery.
5. Canvas Flying particles, cuts, abrasions, and machinery.
6. Chemical resistant Acids and alkalis.

fabric
7. Reflective fabric Hot liquids.

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Annexure – IV
USE OF RESPIRATORY PPE FOR DIFFERENT TYPES OF HAZARDS (Based on IS 9623)
Sl. No. Type of Hazard PPE Specified Remarks
1. Dust or fume (a) Dust respirator

(b) Air line respirator
2. Gas or vapour(non- (a) Cartridge respirator
toxic) (b) Air line respirator
3. Gas or vapour (a) Canister respirator For IDLH
(toxic) (b) Self-contained situations, only SCBA is
breathing apparatus recommended. Level of
(c) Air line respirator contaminant in air should be
known.
4. Dust, gas and (a) Cartridge respirator

vapour (non- with particulate filter
toxic) (b) Air line respirator
5. Dust, gas and (a) Canister respirator

vapour (toxic) with particulate
filter
(b) Self-contained
breathing apparatus
(c) Air line respirator
6. Oxygen (a) Self-contained
deficiency (O2 < breathing apparatus
(b) Air line respirators
19%)
apparatus
7. Toxic substances Positive-pressure-
that can be ventilated plastic suits.
absorbed
through skin

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Annexure – V
PROTECTION FACTORS OF RESPIRATORY PROTECTIVE EQUIPMENT AS PER BRITISH
STANDARD
The efficiency of a respirator is expressed in terms of protection factor (PF) which is defined as follows:
Protection Factor = ambient air concentration /concentration inside face-piece

The values of protection factors for all the types of respiratory protective equipment are not given in BIS
publications. However, the value of protection factor needs to be specified for procuring a suitable type of
respiratory PPE for adequate protection of the user. Such values, known as nominal protection factors (NPF), are
contained in the British Standard Publication BS: 4275-1974 and the typical protection factors for various
respiratory PPE are as listed below for guidance:
Respiratory Protective Equipment Nominal Protection

Factor
Single-use filtering facemask 6 to 20
respirator
Half-mask respirator (cartridge type) 10 to 20
Full-mask respirator (canister type) 40 to 1000
Powered air purifying respirator 20 to 500
Powered visor respirator 10 to 20
Fresh air hose apparatus 50 to 2000
Compressed airline apparatus 1000 to 1,00,000 *
Self-contained breathing apparatus 2000 to
10,00,000*

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Manual
Annexure – VI
ASSIGNED PROTECTION FACTORS OF RESPIRATORY PROTECTIVE EQUIPMENT FROM
ANSI Z88.2 (1992)
Respiratory Inlet Covering

Half Full Face- Helmet/ Loose- Fitting Face-
Type of Respirator Piece
Mask Piece Hood
Air purifying 10 100
Atmosphere-supplying
SCBA (demand -type) 10 100
Airline (demand-type) 10 100
Powered air-purifying 50 1000 2 1000 2 25
Atmosphere-supplying air-line
type
Pressure-fed demand type 50 1000 — —
Continuous flow 50 1000 1000 25
Self-contained breathing
apparatus
Positive pressure — 3 — —
(demand open/closed circuit)

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Issue Revision Page Prepared Approved DAR

Esablished /Revised; Reviewed / Communicate; Group Reviewed; Accepted / Approved;

Safety Engineer CRAI

Document: Revision Number: 00

4. Roles & Responsibilities

4.1 Operation Manager / Division Manager and Project Managers

These appointment holders must have a legal responsibility to ensure that:

4.2 Engineers / Safety Officers/ Supervisors

These appointment holders have a legal responsibility to ensure that:

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Workers should ensure that:

6. Hierarchy of Control & Personal Protective Equipment

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7.1 Guidelines for selection:

Match PPE to Hazard

8. Eye & Face protection

8.1 Over Glass Safety Goggles/ Safety Clip-ons

8.2 Types of Eye & Face Protection

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11. Ear Protection

12. Body Protection

13. Respiratory Protection

13.1 Selection of Respiratory PPE

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Environment Classification for Selection of Respiratory Protection Devices

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14. Foot Protection Equipment

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14.1 Care for Foot Protection equipment

15. Full Body Harness

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15.1 Care of Safety Belts and Harness

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Sl. No. Material Protection Against Hazard

1 Asbestos Sparks, hot materials and heat.

2 Chrome leather Sparks, hot materials, hot liquids, flying particles

3 Flame-proofed duck Sparks, hot materials, heat, flying particles and

5 Rubber Materials causing dermatitis, hot liquids, moisture,

6 Fibre metals Sparks, flying objects, flying particles, cuts, and

7 Chemical resistant Acids and alkalis.

8 Reflective fabric Hot liquids.

Document: Revision Number: 00

Sl. No. Type of Safety Protection Against Hazard

2. Non-skid shoes Moisture.

4. Chrome leather Sparks, hot materials, heat and hot liquids.

5. Rubber Hot liquids, moisture, acids and alkalis, electric shock

6. Conductive rubber Explosive.

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Sl. No. Material Protection Against Hazard

1. Asbestos Sparks, hot materials and heat.

4. Rubber Hot liquids, moisture, acids and alkalis, electric shock,

5. Canvas Flying particles, cuts, abrasions, and machinery.

6. Chemical resistant Acids and alkalis.

Document: Revision Number: 00

Sl. No. Type of Hazard PPE Specified Remarks

1. Dust or fume (a) Dust respirator

4. Dust, gas and (a) Cartridge respirator

5. Dust, gas and (a) Canister respirator

Document: Revision Number: 00

Protection Factor = ambient air concentration /concentration inside face-piece

Respiratory Protective Equipment Nominal Protection