SAFETEY MANUAL

Project Name:- Bon Ami Project at kamsar , SECTION :-D

Guinea
Client Name :- Dynamic mining PAGE :-1 of
Contractor Name :-GLOBAL ARCHER REVISION NO. :- 0
Construction & Engineering DATE :- 01.SEP.2021
SEAFETY MANUAL APPROVED BY:- MD

SAFETEY MANUAL

PQP Prepared by Reviewed by Quality Approved by PM (Site)

Manager

Name:

Date:

Signature:
 SAFETEY MANUAL

2021

Safety Manual for Works

Abstract

Construction Industry is highly prone to hazards related to site activities and construction
projects engage large number of contract workers. Contract workers come from varied trades
especially from rural areas and agricultural background and do not have proper training in
construction safety. During execution at site, these workers are exposed to various risks
involved in construction works and other occupational diseases and health hazards which cause
injuries and illnesses. As a result, the construction projects get delayed due to loss of working
hours and other legal hassles. Therefore, it is essential for any construction project to have
certain safety guidelines for site activities and to create awareness among the workers, site
supervisor and engineers. The aim of the Construction Safety Manual is to enable to
maintain safe working condition at all construction sites under Architecture and Civil
Engineering Division. This manual covers safety policy, principles and objectives of Architecture
and Civil Engineering Division, general guidelines on safe working procedures for various
construction activities, Site Level Safety Committee responsible for implementation of these
procedures, monitoring and reporting procedures and training and awareness building
programmers. This manual also includes annexures containing various formats to be followed
for implementation of safe working procedure and legal compliance.
 CONTENTS
Page No.

1. Definition and Scope

2. Safety Principles and Objectives
3. Safety Policy
4. Safety Organization
4.1. Site Level Safety Committee
4.2. Safety Officer and Safety Steward
4.2.1. Duties of Safety Officer
4.2.2. Facilities to be provided to Safety Officer
4.2.3. Qualifications of Safety Officer
5. General Safety Provisions
5.1. Work Planning
5.2. Job Hazard Analysis Report
5.3. Work Permit
5.4. Safe Working Procedure
5.4.1. Guidelines for General And Enabling Works
5.4.2. Demolition
5.4.3. Piling
5.4.4. Earthwork in Excavation and Backfilling
5.4.5. Reinforcement and Concrete Works
5.4.6. Scaffolding and Working at Height
5.4.7. Construction Machinery and Tools
5.4.8. Structural Steel Fabrication
5.4.9. Electrical Safety
5.4.10. Fire Safety
5.4.11. Housekeeping
5.4.12. Safe Access to Workplace
5.4.13. Common Hazards
 5.5. Personal Protective Equipment
5.6. General Health Management at site
5.6.1. General
5.6.2. First Aid Facility
5.6.3. Fulltime Medical Attendant
5.6.4. First Aid Box, Medicines and Medical Equipment
5.7. Hygiene At Work Place
6. Monitoring and Reporting
6.1. Walkthrough Survey
6.2. Records
6.3. Inspection And Safety Audit
7. Training and Awareness Building Programme
7.1. Safety Event Calendar
7.2. Safety Induction Training
7.3. Pep‐talk, Tool Box Training
7.4. Sign boards, Posters, Displays
8. SECURITY POLICY
9. CONVEYOR BELTS SAFETY PROCEUDRE
10. compressed air system
11. WASTEWATER TREATMENT
12. Hazardous Substances and Dangerous Goods Procedure
13. Health and Hygiene
(a) Malaria Control Procedure
(b) COVID-19 Management Plan & system
14. References
 List of Annexures Page No.
Annexure 1 : Format for Legal Register
Annexure 2 : Format for Job Hazard Analysis Report
Annexure 3 : Format for Work Permit
Annexure 4 : Application for Height Pass
Annexure 5 : Format for Safety Checklist for Heavy Duty Tower /
Scaffolding Erection
Annexure 6 : Format of Certificate of Test and Thorough Examination of Crane
By Third Party
Annexure 7 : Format of Certificate of Test and Thorough Examination of Hoist
By Third Party
Annexure 7A : Register of Periodical Test – Examination of Lifting Appliance
And Gears, etc.
Annexure 8 : Content of a First Aid Box
Annexure 9 : Articles for Ambulance Room / First Aid Post
Annexure 10 : Format of Observation Register or Complaint Records
Annexure 11 : Form No. SGCW‐1
Annexure 12 : Form No. SGCW‐2
Annexure 13 : Format for Injury Report for Contract/Casual Worker
Annexure 14 : Format for Inspection of Fire Extinguishers
Annexure 15 : Format for Testing of Portable and Other Electrically
Operated Equipment
Annexure 16 : Abbreviations
1.1 DEFINITION AND SCOPE:

1.2 Definition:
Construction: Construction is the process of making, building, fabrication and/or erection
of structures for some facility to be housed in the same.
Safety: Safety is the state of being safe or free from any kind of hazard.
Contract: A contract is a legally binding mutual agreement between the parties identified
in the agreement to fulfil all the terms and conditions outlined in the agreement.

1.3 Scope: The manual covers Civil and Public Health construction safety and the scope of
this safety manual shall be for all the construction activities undertaken by Architecture &
Civil Engineering. This manual may be referred to for any Civil and Public Health
construction works and facilities.

2.1 SAFETY PRINCIPLES AND OBJECTIVES:

2.2 Safety Principles:

2.2.1 Ensuring safety at construction sites is mandatory requirement as it is directly
related to welfare of staffs and contractors’ workers.
2.2.2 All accidents and occurrences of near‐misses can be avoided by proper planning
and thorough implementation of safe practices at work place.
2.2.3 All types of injuries, fatalities, loss of property and time can be minimized through
preventive measures.
2.2.4 To increase the safety consciousness of the workforce and the supervisory staffs
through continuous training and motivation towards safe practices.
2.2.5 Regular monitoring, inspections and safety audits will form an integral part of the
safety programs at the worksite.

2.3 Safety Objectives:

2.3.1 To provide a safe working environment to all workers and supervisory staffs.
2.3.2 To ensure safety at each and every level of the project as an integral part of the
activities.
2.3.3 To enhance the safety standards as a continuous effort.
2.3.4 To complete project in an incident‐free manner, without any damage to health,
property and environment.

3.0 SAFETY POLICY:

GACE is committed to ensure the highest standard of occupational health, safety and
environment in all construction activities undertaken in order to achieve zero‐accident
working period in all projects and thereby contributing towards enhancement of the
safety performance of the centre.
4.1 SAFETY ORGANIZATION:
Contractor shall form a Site Level Safety Committee (SLSC) comprising employees from all
sections and one representative from the department. As per chapter XXI, Rule 208,
Central Rules 1998, SLSC shall be constituted by the contractor (Employer) wherein 500 or
more workers are employed. In addition, the corporate office of the contractor shall have
a safety and environmental control section to liaise with the Competent Authority and
carry out periodic safety audit at site. Contractor shall not be self‐ complacent with mere
compliance with sections and rules of various Acts and Rules applicable to construction
safety. He shall promote health, safety and environment practices by identifying the
personnel and assigning specific responsibilities to them so that proper safety is
implemented at site and a safety culture is created among his all employees and
workmen and maintained until completion of the project.

4.2 Site Level Safety Committee: (SLSC)

For a project site having maximum strength of less or equal to 500 numbers of workers,
Contractor shall identify a Site Engineer to perform the duty of the Safety
Engineer/Officer at site. The numbers of representatives from the contractor and the
workers in the Site Level Safety Committee (SLSC) shall be as per chapter XXI, Rule 208,
Central Rules 1998. The committee shall meet at regular intervals, at least once in every
month and shall be chaired by the senior most person having over all control of the affairs
of the construction site, normally the Project Manager or the authorized signatory (power
of attorney holder) of the contractor with Safety Officer as Member Secretary. All section‐
in‐charges including site engineers, electrical, mechanical, QA/QC, Stores, administration
section, representatives of the workers and one representative of the department shall
be the members of this committee. The duties of the committee are enlisted as under:

The main job of the Site Level Safety Committee is to ensure health and safety of all
employees, workers and the neighborhood and for this the committee shall ‐
(a) See that all the provisions of relevant Acts & Rules and conditions referred in
contract agreement are conformed to.
(b) See that a well-documented safety program me exists.
(c) See that a work permit system exists for all construction activities, especially for‐
(i) Any work at hazardous locations such as at height or at depth;
(ii) All hot jobs, fabrication works and electrical repairs & maintenance works;
(iii) All concreting works; and
(iv) Under high noise and high dust environment.
(d) See that all employees are informed of the hazards involved in their work and are
provided with adequate protective equipments.
(e) See that the work environment and the neighborhood is free from debris, muck,
insects and any unhygienic conditions at any time and proper access and
illumination is ensured at the workplace.
(f) See that a detailed schedule for periodic calibration and preventive maintenance
of all the machinery and equipments is being implemented.
(g) See that periodic medical examination of all employees and workers are carried
out to the extent required as per the work environment.
(h) Assess the potential hazards and dangerous occurrences at the work place and
examine the effectiveness of the safety and control measures.
(i) See that various processes of construction and disposal of debris and effluents are
safe to ensure conformance to the Environmental Protection Act, 1986.
(j) Discuss accidents and dangerous occurrences at the work place and examine root
causes of accidents and suggest to the management necessary improvements.
(k) Organize safety circles in the site for developing safety culture.
(l) Investigate complaints received from anybody about the risks or dangers.
(m) Promote safety and health by organizing accident prevention programs,
campaigns and meets on continual basis by organizing safety weeks, safety
competitions, safety talks and film shows on safety, displaying posters and other
promotional activities to stimulate interest among staff and workers about safety.

The agenda and minutes of the meeting to be circulated to all concerned. The decisions
and recommendations of SLSC shall be complied with by the contractor within
specified/reasonable time.

4.3 Safety Officer and Safety Steward:

General: Number of Safety Officers and Stewards: The number of Safety Officers and
Stewards to be engaged by the contractor shall be as per Chapter XXI, Rule 209 and
schedule VIII of Central Rules, 1998. For a project site having maximum strength of less or
equal to 500 numbers of workers, Contractor shall identify a Site Engineer to perform the
duty of the Safety Engineer/Officer at site. The above provision does not absolve the
concerned Site Engineers / Section‐In‐Charges of the Contractor from the responsibility of
ensuring safe working condition for the workmen deployed at a particular area under
their control. The respective Site Engineer stands equally accountable for occurrence of
any near‐miss and / or any accident at site and the Department reserves the right to take
suitable actions, as deemed fit, against the Contractor’s personnel responsible for such
lapse in ensuring proper safety at site.

4.3.1 Duties of Safety Officer: The duties of Safety Officer shall be to advise and assist the
management in the fulfilment of its obligations, statutory or otherwise, concerning
Atomic Energy Factory Rules, 1996, Act & Central Rules, prevention of personal injuries
and maintaining a safe working environment. These duties shall include the following,
namely:‐
(a) to advise the concerned departments in planning and organizing measures
necessary for creating a safe working environment for all workmen engaged at
site and to prevent any kind of personal injuries and damage to property;
(b) to advise on safety aspects in all job studies, and to carry out detailed job safety
studies of selected jobs and to formulate Job Hazard Analysis Report and Safety
Manual during initial mobilization stage of the project;
(c) to check and evaluate the effectiveness of the action taken or proposed to be
taken to prevent personal injuries and damage to property;
(d) to ensure that all Personal Protective Equipment (PPE) provided to workers as
required under any of the provisions of the Act or the Rules conform to the
relevant Indian Standards and to advise all Site Engineers / Section‐In‐Charges /
Supervisors to ensure proper use of such PPEs by workers at site;
(e) to provide advice on matters related to carrying out site safety inspections, daily
walk‐through surveys, etc.;
(f) to carry out site safety inspections in order to observe the physical conditions of
work and the work practices and procedures followed by workers and to render
advice on measures to be adopted for removing the unsafe physical conditions
and preventing unsafe actions by workers;
(g) to render advice on matters related to reporting and investigation of industrial
accidents and diseases;
(h) to report and investigate all accidents and near‐misses and to recommend the
preventive measures so as to ensure non‐occurrence of such cases;
(i) To investigate the cases of industrial diseases contracted and reportable
dangerous occurrences.
(j) to advise on the maintenance of such records as are necessary relating to
accidents, dangerous occurrences and industrial diseases;
(k) to promote setting up of Site Level Safety Committee (SLSC) and to act as adviser
and catalyst to such committees;
(l) to organize in association with the concerned departments, campaigns,
competitions, contests and other activities which will create awareness and will
develop and maintain the interest of the workers in establishing and maintaining
safe conditions of work and procedures; and
(m) To design and conduct either independently or in collaboration with the training
department, suitable training and educational programmer for the prevention of
personal injuries.

4.3.2 Facilities to be provided to Safety Officers: The Contractor shall provide each
Safety Officer with such facilities, equipment and information as are necessary to enable
him to discharge his duties effectively. Such typical facilities may include personal
computer, testing facility, facilities for storage of PPE, documents and stationery, etc.
 4.3.3 Qualifications for Safety Officer:
A person shall not be eligible for appointment as a Safety Officer unless he
a) possesses‐ (i) a recognized degree or equivalent in any branch of engineering or
technology and has had practical experience of working in a construction project site in
supervisory capacity for a period of not less than 2 years; or
(ii) A recognized diploma or equivalent in any branch of engineering or Technology and
has had practical experience of working in a construction project site in supervisory
capacity for a period of not less than 5 years;
(b) possesses a degree or diploma in industrial safety recognized by the Central / State
Government in this behalf; and
(c) Has adequate knowledge of the language spoken by majority of the workers in the
region in which the construction project site where he is to be appointed is situated.

5.1 GENERAL SAFETY PROVISIONS:

5.2 Work Planning: The contractor shall identify the requirements of good practices at
site for fulfilment of legal requirement related to environment, occupational health and
safety. The contractor shall enlist all the activities under the contract in advance and their
effect on safety, health and environment. The contactor shall establish, implement and
maintain procedure to identify and have accesses to applicable legal requirements related
to environment, occupational health and safety. The contractor shall maintain register
(Refer Annexure‐1) of applicable legal requirements which shall be kept updated from
time to time.

5.3 Job Hazard Analysis Report: Contractor shall analyze job‐specific hazards in order to
identify the probable causes to these hazards, well in advance, and recommend the
remedial measures in Job Hazard Analysis Report (Refer Annexure‐2); which shall be
submitted to the Department within one month from the issue of work order in the
approved format and as per guidelines of the Engineer‐In‐Charge for approval of the
Competent Authority as per regulatory requirement of GACE Contractor shall implement
the recommended remedial measures at site in order to create and maintain an accident‐
free working condition at site.

5.4 Work Permit: The contractor’s Site Engineer shall seek work permit for all new
activities to be taken up at site and submit the form duly signed by him in quadruplicate
(Refer Annexure‐3) to Safety Officer before commencement of the work daily. The Safety
Officer will inspect the site and give the clearance to the concerned site engineer. One
copy of the work permit shall be made available with the contractor’s site engineer, site
supervisor, safety officer and departmental staff each. No work shall commence at site
without approved work permit. In case of renewal of work permit, such noting shall be
made on the work permit.
5.5 Safe Working Procedure:
5.5.1 Guidelines for general and enabling works:
The contractor shall submit the layout of proposed location of site office, stores,
batching plant & silos, mechanical workshop, electrical panel rooms, water points,
first aid centre and safety office and other temporary structures for prior approval
of Engineer‐in‐charge. It shall be ensured that the proposed locations of
temporary structures do not hinder the existing permanent structures, roads,
drains, services, movement of workers and equipment during construction, etc.
and shall be easily accessible. The trial pit location for finding existing
underground services shall also be submitted for advance approval.

5.5.2 Demolition:
Before any demolition work is commenced and also during the progress of the
work:
a) All roads and open area adjacent to the work site shall either be closed or
suitably protected. Appropriate warning signs shall be displayed for cautioning
persons approaching the demolition area. The area shall be cordoned off
properly.
b) Protection of adjacent building, underground service lines should be ensured.
Underpinning operations shall not be permitted unless adequate measures
against collapse of structure are ensured.
c) Before demolition operations begin, the Contractor shall ensure that
the power on all electric service lines is shut off and the lines are cut or
disconnected at or outside the demolition site. If it is necessary to maintain
electric power during demolition operation, the required service lines shall be
adequately protected against damage.
d) Persons handling heavy materials /equipments shall wear safety shoes.
e) No floor, roof or other part of the building shall be overloaded with debris or
materials that may render it unsafe.
f) Entries to the demolition area shall be restricted to authorized
persons only.

5.5.3 Piling:
5.5.3.1 Piling rig: The legs of the tripod shall be properly spiked in the ground to prevent
accidents due to slipping of the tripod legs when rested on a paved ground or sleepers.
The shear legs and bases become thin and fatigued with usage. They should be replaced
frequently.
5.5.3.2 Pulley and rope: The pulley and rope shall be checked with reference to the Rule
71 and 72, Section‐ I of BOCW Central Rules, 1998. In addition to this, the pulley and rope
shall be checked before the commencement of day’s work, in this respect‐
a) Check for loose strands and wear, deformation, corrosion and breakage of wires.
b) Check whether the end of the rope has become loose or has slipped wire clips or
wire sockets.
c) Check against slippage of rope from the sleeve during work.
d) Check if there is any occurrence of torsion in the wire rope while working and if
so, unwind it normally at once.
e) Check if there are any adhesions like mud, earth, etc, on the rope. If so, clean with
wire brush or compressed air.
f) Check if the grease applied on the rope is adequate.
g) Check for wear and cracks on the lining of the clutches and brake band; and the
engine condition.
h) The pulley shall be checked for any cracks in wheel, etc.
5.5.3.3 Field operation: Contractor shall take following precautions during boring of pile
and concreting activity:
 Centering the Pile — the workers helping while marking the pile centre shall be
protected from possible injury by bailer / chisel.
 Driving the casing & cap — workers shall be protected from chances of slippage of
driving bar / clutches falling accidentally.
 Lowering Reinforcement Cages — the lifting and lowering of re‐bar cage shall be
done with utmost care since it is very heavy and at the same time flexible enough
to buckle. Adequate supporting arrangement shall be ensured. The workers shall
be protected from projected parts like binding wire, wire nails, etc. while
preparing the pile cages or handling and lowering them.
 Jammed Casings — while withdrawing the casing, sometimes the casings may get
jammed. During the process of extracting them, the tripod legs shall be secured
properly for prevention of toppling / collapse of tripod due to sudden jerks. The
withdrawal process of casing shall be executed slowly and with proper care in
order to ensure smooth movement of the casing.
 Grounding the Bailers/Chisels — workers shall keep safe distance while the bailers
and chisels are grounded so as to be safe from any injury due to swing of them.
Minimum distance of 5 m shall be maintained.
 Guarding of flywheels – the flywheels of the machine of the piling rigs shall be
guarded properly.
 General precautions — workers shall wear tight fitting clothes and all necessary
PPEs. Care shall be taken for nearby permanent structures for vibrations, etc.
during piling.
5.5.4 Earthwork in excavation and backfilling: The Contractor shall take all safety
precautions during the execution of awarded work and shall maintain and leave the site
safe at all times.
5.5.4.1 Excavation:
5.4.4.1.1 All trenches 1.2 m or more in depth shall at all times be provided with at least
one ladder at a spacing of 15m or part thereof in case of hazardous work and 30m or part
thereof in case of less hazardous works. Ladder shall be extended from bottom of the
Trench to at least 1 m above the surface of the ground and the legs of the ladder shall be
secured against slipping.
5.4.4.1.2 The sides of the trench which are 1.2 m or more in depth shall be stepped back
to give suitable slope (angle of repose depending on the type of the soil) or securely held
by steel or suitable shoring, so as to avoid the danger of sides from collapsing. A provision
of clear berm of a width not less than one‐third of the final depth of excavation is
recommended. In areas, where this width of the berm is not feasible due to space
constraint, the clear berm width (clear space) not less than 1 m shall be provided. Cutting
shall be done from top to bottom. Under no circumstances mining or under‐cutting shall
be done.
5.4.4.1.3 The Contractor shall ensure the stability and safety of the excavation, adjacent
structures, existing services and the works of other agencies.
5.4.4.1.4 Open excavations shall be cordoned off by suitable railing/barricading and
photo‐luminescent warning signals installed so as to prevent persons slipping or falling
into the excavations. Warning signals shall be visible at night also and the area shall be
well illuminated during the work.
5.4.4.1.5 All blasting operations, if permitted by Engineer‐in‐charge, shall be carried out
on the basis of procedures approved by Inspector of Explosives. All works in this
connection shall be carried out as per I.S Code of Practice. Barricades, photo‐luminescent
warning signs, etc. shall be placed on the roads/open area. Prior approval of such
operation shall be obtained from Safety Officer/Engineer‐In‐Charge of Works.
5.4.4.1.6.
a) For removal of earth from an earth mound work permit shall be obtained from
the Engineer In‐charge / safety officer of the work.
b) As far as practical, earth shall be removed mechanically. Ramp shall be made by
the contractor with suitable hard material for movement of trucks / tippers, etc.
with proper slope, compaction and drainage so as to ensure safe and easy
movement of the above transport vehicles carrying excavated earth.
c) Wherever manual removal of earth is involved, earth shall be removed from the
top by maintaining the proper slope equal to the angle of repose of the earth.
d) Such work shall be constantly supervised by the contractor's responsible person
and frequently inspected by the departmental representative to ensure that no
under‐cutting is done.
e) The excavating equipment should be parked at a distance of not less than the
depth of the trench.
f) For excavation in greater depths, separate access for workers with proper
steps/slope and temporary railing arrangement shall be provided apart from
ladders. The access shall be maintained in proper condition until backfilling is
completed in the excavated area.
g) Experienced and qualified supervisors shall be put in charge of the excavation
work by the contractor. The supervisor shall brief workers about the working plan
before the commencement of work and explain potential hazards to them. He
 Shall pay attention to existing water pipelines, electric cables below the surface or
during excavations of underground structures and arrange for proper protection
to them. Contractor shall report the condition of excavated pit to departmental
staff/Engineer‐in‐charge after every rain and accordingly shall take necessary
corrective action for safety at site.
h) Contractor shall arrange adequate and efficient mechanical dewatering system
as recommended by Engineer‐in‐charge. These pumps shall be inspected and
maintained in proper working condition. The electrically operated pumps shall be
connected to ELCB of proper rating for safety of the person operating/shifting
them.
i) Contractor shall wash the wheels, of the transport vehicles carrying excavated
soil, with water jet before moving out of the site premises so that there is no
spillover of soil on the existing roads. In case there is any such spill over on the
roads, the same shall be cleaned by the contractor by manual / mechanical means
immediately at no extra cost.

5.5.4.2 Backfilling:
5.4.4.2.1 The earth to be used for backfilling shall be taken from approved location or
borrow pit if the soil is taken from inside BARC. For outside GACE supply, the source shall
be approved by the Department in advance.
5.4.4.2.2 The contractor shall take precautions for earth mounds stacked for backfilling as
mentioned above under the head of earthwork in excavation. The soil shall not be pushed
indiscriminately by mechanical means into the excavated pit as far as possible. If
mechanical dumping / pushing are unavoidable, it has to be done with proper guidance /
warning (helper / reverse horn to be provided to all vehicles) and the pits have to be
vacated from manpower.
5.4.4.2.3 The final backfilling shall be done in layers and compacted as per technical
specification of the tender. Utmost care shall be taken by the contractor for protection of
permanent structure or already cast structures during use and movement of mechanical
compactors.
5.4.4.2.4 The temporary power supply points or panels are to be protected from water
spraying or any other damages during backfilling process.

5.5.5 Reinforcement and Concrete works:

5.5.5.1 Concreting:
a) Manual handling of concrete shall be restricted as far as possible. Proper exhaust
ventilation shall be available at the cement store and during casting work in confined
places. PPE for protection of workers viz. respirators, hand gloves, gumboots, etc. shall be
provided by the contractor to the workers handling cement bags and concrete manually.
b) The contractor shall provide ear‐muffs to the operator / worker exposed to continuous
high‐level of noise and ear‐plugs to all workers involved in the concreting work.
c) The out riggers / wheels of concrete pump / concrete mixer shall be placed on firm
ground / platform. Pump accessories shall be checked for its safe working pressure
considering maximum pipe line height. A pressure release valve shall be attached to the
pump to release the excess pressure.
d) The pipeline for transporting the concrete shall have the shortest route with minimum
bends and shall be installed on firm supports at suitable intervals. Pipeline shall be
properly joined with clamps and securely tied to nearby support and checked in advance
before starting the concreting. Pipe segments shall be cleaned in advance to avoid
choking of concrete during casting.
e) Length of flexible hose shall be such that it can be easily handled by the workers. The
end of flexible hose shall be checked before commencement of concreting and it shall be
free from loose wires, concrete lumps, etc. The “swan neck” position of the flexible hose
shall be avoided as it results in building up excessive pressure on concrete pump and
clogging of concrete.
f) Ball catcher / Trap to arrest the ball must be provided at the end of the pipe line after
the concreting is over and flexible pipe is removed. The supervisor, who is authorized to
give clearance for ball passing, shall check that whether the ball catcher / trap is fixed
properly before passing the ball. The supervisor shall instruct all workers to keep safe
distance during ball passing.
g) Signaling system ‐ Red and green flags shall be displayed by the supervisors/
designated signalmen, standing in visible locations, for commencement and stopping the
flow of concrete. These signalmen shall not be engaged in any other work during
concreting activity. They shall be trained along with the concrete pump operator in
advance by the contractor for correct signaling. During concreting in night, electric
torches fitted with red/green cellophane papers may be used instead of red/green flags.
h) All mechanical equipment/tools used in concreting activity like batching plant/concrete
mixer, concrete pumps, vibrators, etc. shall be operated by trained person only.
i) Ready Mix Concreting – Loaded transit mixers shall move / park on firm ground as far as
possible. The reversal of transit mixers shall be guided by helpers and reverse horn shall
be used for reversal. Cleaning/washing of transit mixers shall be done at designated area
only.
j) The concrete mixers used for preparation of concrete may be tilting or non‐tilting type,
driven by electric motors or by diesel engine depending upon the location of the
structure. For electric driven mixers, the wire connecting the mixers shall be in good and
sound condition, and the circuit breaker shall be well maintained.
k) Exhaust gases of a diesel engine if inhaled for long period may cause diseases. They
shall be directed away from the operator. All gears and moving parts shall be well
guarded. Care shall be taken to display notice “Under Repairs” while cleaning the drum.
Wire ropes operating the drum and clutches shall be inspected regularly and replaced, if
required.
5.5.5.2 Reinforcement:
a) Bar bending and cutting yard shall be properly cordoned / barricaded and entry shall be
restricted.
b) Re‐bar bending and cutting machines shall be handled by trained operator / skilled
workers.
c) Shifting of cut re‐bars shall be done by mechanical means as far as possible. When re‐
bars are shifted manually, it shall be done with proper care and proper balance shall be
maintained. Clear access shall be provided for shifting of re‐bars.
d) Proper support shall be given to the column bars by means of rings / props against
undesirable sway.
e) Free ends of the binding wires shall be bent inside to avoid injuries.
f) Proper PPE viz. leather / cotton hand gloves, goggles, etc., for the people handling /
shifting and cutting / tying of re‐bar, shall be used for protection from injury and other
occupational diseases.

5.5.5.3 Formwork for concreting:

a) Shuttering and supporting members viz. props, tie rods, etc. shall be of adequate
strength to support the load / pressure of concrete and the formwork scheme shall be
approved by Engineer‐In‐Charge in advance. The procedure approved by Engineer‐In‐
Charge shall be followed for mixing, transporting and pouring of concrete.
b) The process of stripping of formwork shall be planned in advance and approved by
Engineer‐in‐charge. Stripping shall enable the structural member to behave in desired
manner. The area shall be suitably cordoned / barricaded and unauthorized entry shall be
restricted by displaying signboards, etc.
c) While removing formwork from vertical surfaces, the shuttering board shall be
adequately supported by props, in order to prevent the same from toppling / slipping,
until it is lowered on ground safely. Same support with props shall be provided during
erection of formwork too until the plywood is secured in desired place with tie rods.

5.5.6 Scaffolding and Working at Height:

5.5.6.1 General:
a) All the workers, supervisors and engineers of the contractor, who will work at height,
shall have valid height passes issued as per Annexure‐4 by the Safety Officer / Medical
Attendant in consultation with the Authority of the Safety Unit, ESG, BARC. Each such
individual shall be medically examined by a Medical Practitioner, for blood pressure,
vision, hearing, and efficient movement of limbs, epilepsy, vertigo or any other persistent
diseases that make him/her medically unfit for working at height. The fit persons shall be
issued height passes, which shall be valid for maximum 6 (Six) months, for working at
height. After every 6 (Six) months, these persons shall be medically examined in order to
find out their fitness for working at height. List of unfit workers shall be submitted to the
departmental representative and such persons may be allowed to work at ground level
and in no case shall be engaged by the contractor to work at height. The records of
Medical checkups / fitness tests certified by the Medical Practitioner shall be maintained
at the first aid centre / safety office of the contractor and shall be produced to the
departmental representative as and when asked.
b) The scaffold to be erected for working at height shall be designed for the estimated
load (load of the RCC structure to be supported, live load and other vibrations load during
casting, etc.) and design shall be submitted for approval of the department in advance.
The scaffold components shall be designed for at least 4 times of the maximum intended
load. The use of Bamboo/Wooden scaffoldings shall not be permitted irrespective of
height of work and only steel scaffolding shall be used by the contractor.
c) The erected scaffold shall be inspected and cleared by the safety officer of the
contractor. The safety check list (Refer Annexure‐5) for scaffolding erection shall be
submitted by the site engineer of the contractor to the safety officer in triplicate. The
standard format of safety check list for scaffolding erection is enclosed as Annexure‐ 5.
The safety officer shall physically inspect the erected scaffolding and after his satisfaction,
shall give clearance for the use of the scaffold. One copy of safety check list, duly filled in
and cleared by safety officer of the contractor, shall be submitted to the departmental
representative. Other two copies shall be available with site engineer and safety officer
of the contractor respectively.
d) Base of the structure shall be supported on levelled and firm ground as far as possible.
In case such firm ground is not available at site then the load of the vertical members of
the scaffold shall be distributed with the help of base plates, sole plates or channels, etc.
The base of the scaffold shall be away (at least 1.5m) from excavated pits, open drains,
manholes, water logged area, etc. Contractor shall ensure that there is no vehicle
movement near the erected scaffold and it shall be protected by proper
barricading/warning sign, etc.
e) The scaffold shall be checked for its condition i.e. it shall be free from bends, cuts, rust,
etc. All vertical members shall be in plumb and correctly spaced. The joints of vertical
and horizontal members shall be properly connected with couplers, lock pins, etc. The
scaffold shall be securely tied with permanent structure as per the requirement of IS:
3696 – 1991 (Part 1) (Reaffirmed in 2002).
f) The access to the scaffolding shall be free from obstructions, undesirable and slippery
materials. Stair tower, monkey ladders, gangway, etc. shall be provided in the scaffolding
for movement of the workers.
g) The working platform and the access to the scaffold shall be free from all debris and
loose materials.
h) The diagonal face bracing/Zig zag face bracing shall be provided at a spacing of
maximum 10 m centre to centre for pipe scaffolding.
i) Safety tag (for ‘Unsafe Scaffolding DO NOT USE’ in red letters or tag / ‘Safe Scaffolding’
in yellow letters or tag) shall be displayed on the erected scaffold at ground level. Such
safety tag / sign boards shall be written in the language understood by the majority of the
workers. Unsafe scaffolds shall be repaired / removed.
 j) Contractor shall provide necessary PPEs as per relevant I.S. Codes for the workers
working at height viz. full harness safety belt, fall arrestor, kinetic shock absorber, safety
helmet, gloves, etc.

5.5.6.2 Working platform:

a) The quality of wooden planks or MS grill plates for decking of working platform shall be
made of good quality material and free from any defects, etc. The load carrying capacity
of the working platform shall be designed in consultation with Engineer‐in‐charge.
Working platform, gangways and stairways shall be so constructed that they shall not sag
unduly or unequally. They shall be closely boarded, shall have adequate width (at least 2
planks/ grill plates wide or 600 mm whichever is more) for easy movement of persons
and materials and shall be suitably guarded.
b) The steel walkways or wooden planks used for making working platform shall not
project beyond the end supports to a distance of 150 mm. The planks shall be rigidly tied
at both ends to prevent sliding and toppling. The thickness of the planks shall be
adequate to take load of men and materials and shall conform to IS: 3696‐1987 (Part‐I)
(Reaffirmed 2002) and they shall not collapse.
c) The overlaps of MS grill plates / wooden planks shall not be less than 300 mm.
d) The platform shall extend at least 600 mm beyond the end of wall in order to facilitate
the worker to reach end of the wall.
e) All working platforms shall have guard rails at 1.0 m height with middle rails at 0.5 m
height from the platform and 15 cm high toe boards securely tied with the vertical posts.
The spacing of vertical posts shall not exceed 2.0 m centre to centre.
f) Every opening in the floor of a building or in a working platform shall be provided with
fencing or railing and protective cover, to prevent fall of persons or materials, the
minimum height of which shall be 1.0 m, along with 15 cm high toe board at floor level
along the railing. The removal of such railing / protective cover shall be done only after
seeking proper work permit from Safety Officer of the contractor.
g) The contractor shall provide grab rope / life line all around the working platform/level,
at height, which will provide tying / anchoring facility for the safety belt / fall arrestor.
h) Contractor shall provide safety net under all working platform/level at height to
protect fall of men and materials from above and such safety nets shall conform to IS:
11057‐1984.
i) Adequate precautions shall be taken to prevent danger from electrical lines and
equipment. Scaffolding, ladder, working platform, gangways, etc. shall not exist within 5m
of any un‐insulated electric wire. Whenever electric power and lighting cables are
required to run through (pass on) the scaffolding or electrical equipments are used, such
scaffolding structures shall have minimum two earth connections with earth continuity
conforming to relevant IS Code of Practice.
5.5.6.3 Ladder:
a) Safe means of access shall be provided to all working platforms and other
elevated working places with the help of ladders.
b) Ladder shall be placed in an inclination not steeper than 1 in 4 (1horizontal and 4
vertical).
c) Every ladder shall be securely fixed at bottom from sliding/slipping.
d) No single portable ladder shall be over 9 m in length.
e) For ladders up to 3m in length, the width between side rails in the ladder shall be
a minimum of 300 mm. For longer ladders, this width shall be increased by at least
20 mm for each additional meter of length.
f) The spacing of rungs shall be uniform and shall not exceed 300 mm.
g) Ladder shall be of rigid construction having sufficient strength for the intended
loads and made either of good quality wood or metal. All ladders shall be
maintained well for safe working condition. The rungs shall be tested periodically
as per provisions of IS: 3696 ‐1991 (Part 2) (Reaffirmed in 2002).
h) Whenever ladder is not securely fixed an extra worker shall be engaged for
holding the ladder.
i) Ladders shall not be used for climbing while carrying materials in hands. While
climbing, both the hands shall be free for holding the rails. Contractor shall make
alternate safe arrangement for lifting of tools and implements for all his workers
working at height.

5.5.7 Construction machinery and Tools:

General: The operation and maintenance of any construction machinery shall be as per
manufacturer’s guidelines & checklists and by trained personnel only.
5.5.7.1 Earth moving machinery:
General: The contractor shall ensure the stability of the equipment, while working,
depending on the load bearing capacity of the ground; which may reduce due to presence
of moisture and due to vibration effect. The contractor shall provide bearing plates,
packing, etc. to strengthen the ground below outriggers or wheel or crawler of the
equipment. All earth moving equipment shall have Roll over Protective Structures, sound
suppressers, seat belts, reverse alarms, warning horns, windshield wipers and easily
approachable control and lever for brake system and emergency stop. They shall be
checked at the time of delivery and they shall be properly maintained. Contractor shall
display warning sign for keeping away from the moving parts of such equipment and the
area of operation of such machinery shall be properly cordoned. The shovel / bucket of
the earth moving equipment shall be rested on ground when the equipment is not
working. Operation of such equipment shall always be carried out by trained operator
accompanied by the designated helper.
a) Power shovels: The shovels both mechanical as well as hydraulic / pneumatic type
need basic precautions while being operated. The excavators shall not lose their stability
while operating. The Contractor shall adhere to the Load Charts for various boom lengths
Provided by the manufacturers. For the mechanical shovels, the wire rope shall be
changed as per the frequency mentioned in history sheet. For Hydraulic hoses, the
connections shall be tight and leak proof. The fire extinguisher of appropriate type
confirming to IS: 2190‐1992 (Reaffirmed in 2007) shall be made available on the hydraulic
excavator.
b) Bulldozers: The blade of Bulldozer shall be inspected at least once in a week. The
blade shall not be used as a brake except in emergency. The position of the blade shall be
adjusted while travelling up or down the gradient. The Bulldozer shall be parked on
levelled ground, by applying hand brakes and by lowering blade.
c) Scrapers: The brakes of the Scraper shall be checked before putting it in operation. The
scraper bowl shall be repaired and the cutting blades shall be changed periodically. The
bowl shall be locked before carrying out the repairs. The bucket shall be raised while
moving the scrapper. No vehicle movement shall be allowed within the radius of
movement of scrapper and the area shall be properly cordoned. The wire ropes shall be
checked periodically by visual inspection at least once in a fortnight.

5.5.7.2 Lifting and hoisting machinery: Use of lifting machines and tackles including their
attachments, anchorage and supports shall conform to the Rules 55 to 71 of chapter VII
of BOCW Central Rules, 1998 and shall also conform to the following conditions.
(a) Lifting machines and tackles shall be of good mechanical construction,
sound material and adequate strength and free from any defects and shall be kept in
good repair and in good working condition. Every rope used in hoisting or lowering
materials or as the means of suspension shall be as per manufacturer’s guidelines, of
good quality and adequate strength and dimension and free from any defect. Test
certificates of such ropes, D‐shackles, etc. shall be submitted in advance by the
contractor.
(b) Every crane operator or lifting appliance operator shall be properly qualified. No
person under the age of 18 years shall be in charge of any hoisting machine or to give
signal to operator of such machine.
(c) In case of every lifting machine (and of every chain, ring, hook, D‐shackle, swivel and
pulley block used in hoisting or as means of suspension) the safe working load shall be
ascertained and clearly marked. In case of a lifting machine, having a variable safe
working load, each safe working load and the conditions under which it is applicable shall
be clearly indicated. No part of any machine or any gear referred to above in this
paragraph shall be loaded beyond the safe working load except for the purpose of testing.
This shall be approved by the Safety Officer of the contractor.
(d) The Contractor shall notify the safe working load of the machine to the Engineer‐in‐
charge whenever he brings any machinery to site and get it verified by the third party
testing, supported by a valid test certificate.
(e) The base of such hoisting equipment shall be kept in perfect horizontal condition since
any tilt would reduce the load carrying capacity of the equipment. The foundation shall
Be firm enough to support the equipment. The level shall be checked every day before
starting the work in case of mobile hoisting equipment.
(f) Thorough inspection and load testing of lifting machines and tackles shall be done by a
third party, at least once in every 12 months and the records of such inspection and
testing shall be maintained and a copy shall be submitted by the contractor to the
departmental representative at site. Motors, transmission, couplings, belts, chain drives
and other moving parts of hoisting appliances shall be provided with adequate
safeguards. Hoisting appliances shall be provided with such means as it shall minimize the
risk of any part of a suspended load becoming accidentally displaced or lowered.
(g) Double sling shall be used for hoisting material. The angle of the sling shall be wide
enough for safe hoisting and the sling shall be adjusted as per the centre of gravity of the
material to be lifted. A guide rope (manila rope of sufficient length, normally 1.5m long)
shall be attached to the end of the material lifted in order to pull the same conveniently
during lowering.
(h) The contractor shall maintain a Register of Periodical Tests for Examination of Lifting
Appliances and Gears (Refer Annexure 7A) at site as per Rule 74, Chapter VII, BOCW
Central Rules, 1998 and record the periodic / annual thorough examination of such
appliances (viz. winches, derricks, their accessory gears, loose gears, ropes, hooks,
shackles, swivels, etc.). This register shall be kept available at site always for examination
of the department.

5.4.7.2.1 Tower Cranes: Erection & Commissioning ‐ the type of the tower crane to be
used shall be selected based on the load to be lifted, the reach of the boom and the
height at which the material is to be shifted. The contractor shall follow all the safety
instructions given in the manufacturer’s manual for erection, dismantling or extension
(jumping) of tower cranes. The contractor shall submit the operation manual, provided by
the manufacturer, to the departmental representative before erection of the same at site.
For both movable and fixed tower cranes, the adequacy of the counterweight shall be
ensured. The base of the tower crane shall be in perfect horizontal level. Base shall be
capable of bearing the loads during the operation of tower crane.
The foundation of the tower crane (mainly for static tower crane) shall be properly
designed, for at least 25% more than the maximum load carrying capacity of the crane.
For erection of mobile tower crane, the contractor shall first level and compact the soil at
the place of erection or shall lay PCC / RCC of sufficient thickness if the soil condition is
poor. The out riggers / wedge of the mobile tower crane shall be properly secured. The
limit switch of the tower crane shall be properly calibrated and checked periodically by
the contractor in order to ensure safe load carrying capacity of the same. The load
carrying capacity shall be tested, at least once in 12 months, by a third party and a copy of
such test shall be submitted by the contractor to the departmental representative at site.
The limit switch shall function in such a manner that it immediately cuts off the power
supply to the hoisting motor of the crane on overloading. The electrical power supply
system of the crane shall be through MCB / ELCB of proper rating which shall be
 Periodically checked. The height of the tower crane shall be such that it clears all
obstruction like column dowels, protruding parts of scaffolds, overhead electric lines, etc.
easily while hoisting the loads.
Operation – The crane shall never be used to pick the loads which are out of the crane’s
reach or to do skew pulls of any sort. The load (to be lifted by the crane) shall be free from
any sticky characteristic which may cause sudden jerk while lifting. No worker / person
shall be lifted by tower crane. Any kind of swinging of lifted load, to put them out of
crane’s reach, shall not be tried. The operator shall not reverse the motor in order to
achieve quicker stop to save time. He shall execute one operation at a time only and shall
never combine horizontal movement of trolley with vertical movement of lifting hook.
Tower crane shall be protected from sway due to wind load, etc. during operation.
Precautions in high wind load (more than 72 kmph or possibility of storm) shall be taken
as per manufacturer’s guide. Various components and parts of the tower crane like wire
ropes, pulleys, structural members of the tower and boom, etc. shall be periodically
checked and properly maintained by the mechanical engineer of the contractor. Proper
lighting arrangement with the boom and the tower of the crane shall be provided as
safety arrangements for clear visibility during night. The tower crane shall be provided
with the siren / horn facility in order to caution the workers in vicinity during operation of
the crane. The operator shall take “START” and “HOISTING” signal from the designated
helper / supervisor only; however, “STOP” signal can be taken from anyone.
Maintenance ‐ The balancing rope, trolley rope, hoisting rope and erection rope shall be
checked as per maintenance guidelines given by the manufacturer and they shall be
replaced immediately as and when required. For regular maintenance, the manufacturer’s
manual shall be followed.

5.4.7.2.2 Mobile Cranes: The contractor shall take care that, the engine of the crane shall
be kept running with the gear engaged and maintain a slow speed, while moving down the
hill. While travelling uphill or downhill, the boom shall always be kept downhill in order to
prevent the boom from falling back. The soil of working area, movement area and parking
area of the mobile crane shall be well compacted and shall have proper drainage
arrangement. The area shall be dry, levelled and firm enough to hold the load of the
mobile crane. In case the soil is soft, the area under the wheels should be made solid with
stones, wooden slippers, etc. This also applies to the crawler mounted cranes. The chart
for rated load vis‐à‐vis operation radii for mobile crane shall be referred to before any
erection and the same shall be submitted by the contractor to the departmental
representative in advance. In no case, the maximum operation radius shall be exceeded.
The out‐ riggers / jacks along with bearing plates shall be used while in operation and no
load shall come on the wheels. The lifting hook shall be tied / anchored while the crane is
moving or not operational. Before starting operation at the beginning of day’s work, the
capacity load shall be picked up to 0.3 m above the ground to test the drift, if any, due to
faulty brakes. The brakes shall be ‘ON’ when a rubber tier crane is operated. The operator
shall always avoid any jerky start or a fast swing during operation of the crane since it
 Increases the risk of overturning of the crane. The pressure in the pneumatic tier shall be
maintained correctly in all wheeled machines. The crane shall be equipped with the
following features:
i) Anemometer to indicate wind pressure
ii) Anchors for rail mounted cranes
iii) Load Limiter to prevent failure of ropes
iv) Safety stops to restrict crane travel
v) Swinging radius indicator to indicate safe load at given radius
vi) Heel indicators to control crane heeling
vii) Electrical/mechanical safe limits to compare the weight actually hoisted
and the load admissible at various swing radii
The standard formats for inspection and certificate of testing for crane and hoist are given as per
Annexure 6 and 7.

5.4.7.2.3 Builder Hoists: The capacities of the builder hoists are limited. The structure of builder
hoist shall be supported from permanent structure like column, slab, etc. so that the rails do not
rattle while operating the hoist. The structure shall be vertically held in position. Periodic
checking and maintenance shall be done by the contractor for the condition of ropes, rails,
pulleys, bucket/hopper, locking system, etc. from time to time. There shall not be any
obstruction or protruding part on the way of movement of builder hoist. The builder hoist shall
never be used for movement of manpower. The openings shall be cordoned by guard rails as per
safety provisions under working at height.

5.5.7.3 Transporting Machinery:

a) Trucks, tippers, dumpers used in transportation of excavated earth or other materials;
which are loaded with mechanical excavators, shovels / loaders shall have strong
canopies over the driver’s cabin to protect them from injuries while loading. The driver’s
cabin for all the vehicles at construction site shall have a system of sound and vibration
suppression, seat belts, reverse horn/alarm, rear view mirror, wide windshield, triplex
glass, wiper, sun visor, etc. Brakes and control shall be designed so as to get locked when
the vehicle is parked. While going down the gradient, the speed of the vehicle should be
controlled. Hydraulic retarder shall be used for big dumpers. Persons holding valid driving
licenses for heavy motor vehicle shall be engaged as drivers of the respective type of
vehicles. Every dumper, tipper, truck, etc. shall be accompanied by helper and driver shall
take all signals from his helper only. The access road of such transport vehicle shall be
firm and levelled as far as practicable and shall be free from any obstacle.
b) Trucks shall be loaded at places where there is no danger of falling rock or landslide.
While loading trucks with mechanical excavators, shovels, etc. suitable distance shall be
kept to avoid the shovel touching the truck. Brakes shall be applied when a vehicle is
loaded and unloaded. The vehicles shall not be overloaded and the loading shall be even.
Stop logs shall be used while loading and transportation so that the back door of the
dumper does not open undesirably.
 c) For tough riders, the hydraulic system for the bucket shall be checked periodically as
per manufacturer’s maintenance manual. They shall not be overloaded.

5.5.7.4 Concrete mixers and batching plants: The concrete mixers and batching plants shall be
calibrated by the contractor at least once in a month and such records shall be made available to
the departmental staff for record.
5.4.7.4.1 Concrete mixers: The mixer shall be placed on levelled and firm ground. The
hopper shall rest on ground while loading of aggregates and cement. The hopper shall not
be overloaded. The gear, pulley, ropes, etc. shall be checked regularly and replaced as
and when required. Concrete mixers shall be operated by trained / skilled operator only.
In case of electrically operated mixer machines, the switch boxes shall be properly
guarded from rain and dust.
5.4.7.4.2 Batching Plant: The installation, operation, maintenance and decommissioning
of batching plant shall be done as per manufacturer’s guidelines and manuals. All
electrical works and connections shall be done by a licensed electrician under supervision
of electrical engineer of the contractor. The DG requirement (in case of power cuts) shall
be of at least 150% of the overload capacity. The operations of hopper, scrapper and pan
mixer shall be smooth and periodic inspection shall be done as per manufacturer’s
guidelines. The material bins shall be checked periodically for presence of any boulders,
lumps, etc. which may choke in the hopper causing disruption of operation of the
batching plant. Proper care shall be taken during feeding cement silo from the bulker for
any loose joints in the feeder pipe and pump of the silo. The silo shall have a guarded
monkey ladder for access to the top. The person accessing the top of silo shall seek work
permit in advance and shall use proper PPE while climbing. The outer surface of the silo
shall be properly painted and maintained against weathering effects. The contractor shall
make available at least one fire extinguisher near the operator cabin of the batching plant
and the same shall be maintained in good condition at all times. The operator cabin and
the scrapper cabin shall be well ventilated and dust proof. The underground water
tank/Vat of the batching plant shall be covered with suitable protective cover and shall be
cordoned all around.

5.5.7.5 Hydraulic machines: Hydraulic operated machines like mechanical excavators, jacks, or
any other hydraulically operated parts, etc. shall be handled carefully. The pressure relief valves
mounted on the Hydraulic construction equipment shall not be tampered. These machines shall
be equipped with the foam based fire extinguisher. These machines shall be maintained at
regular intervals as per the manufacturer’s manual, to avoid failure of brakes, hydraulic system,
etc. Regular checking shall be done for such equipment for any leakage, condition of the hoses
and connections, etc. Contractor shall give proper training to the operator, mechanic, etc. before
they handle the equipment.
5.5.7.6 Dewatering pumps, Concrete pumps, Boom placer pumps:
5.4.7.6.1 Dewatering pumps: The rotating parts of the dewatering pump shall be well
guarded. Only authorized operator / mechanic shall operate the pump on requirement.
He shall not wear any loose clothes while operating the pump. The exhaust of the smoke
shall be away from the workers working in the surrounding area. The pump shall be
operated and maintained as per the manufacturer’s guidelines.
For electrically operated dewatering pumps including submersible pumps, special care
shall be taken while operating them. Such pumps shall be fitted with ELCB of proper
rating. The power shall be put off before shifting or removal of the submersible pumps.
Only authorized operator / electrician shall be allowed to operate the same.
5.4.7.6.2 Stationery Concrete Pumps and Boom Placer pumps:
The commissioning, operation and maintenance of concrete pumps (both stationery and
boom placer type) shall be done as per manufacturer’s guidelines or manual provided
along with the equipment. The safety procedure and tips as mentioned in these
guidelines shall not be violated. A copy of such manuals shall be submitted to the
department before installing the equipment at site. Apart from manufacturer’s manual,
the following guidelines shall be followed for operation and maintenance of the concrete
pumps:
a) The operation, maintenance and signaling of concrete pumps shall be done by trained
and authorized personnel having minimum 18 years of age.
b) Place of work shall be so selected that the visibility of batching plant operator/transit
mixer driver, concrete pump operator, signal man/supervisor and hose man (at the
pouring point) is ensured all at a time. In case such visibility between all the above people
cannot be ensured, then at least the pump operator shall be able to see the batching
plant operator and signal man separately. The pump operator shall play most important
role in pouring and he shall be properly trained by the safety officer/site Engineer of the
contractor to understand the signaling process properly in order to ensure smooth
concreting activity at site.
c) When the concrete is being placed in the hopper of the pump (either from batching
plant chute or transit mixer chute), no person shall climb on the hopper of the pump.
d) The danger zones (within working area) like hose end position, beneath the placing
boom, moving parts of the concrete pump and its hopper, its support legs and the area of
the concrete pipe line, etc. shall be identified by the safety officer/ mechanical engineer
in advance. Accordingly these areas shall be cordoned and restricted movement shall be
ensured as practicable as possible.
e) The concrete pipeline (delivery system) for stationary pumps shall be checked by the
mechanical engineer before he seeks work permit for concreting activity, for proper
clamping of the pipe joints, supports for pipe line, etc. The pipe line shall have minimum
number of bends and shall be straight as far as possible. In case pipe line needs to change
the direction, then there shall be at least 5 m straight portion just after the concrete
pump. The bends in the pipe line shall be as smooth as possible.
 f) Inspection interval shall be decided based on manufacturer’s guide line, age of the
concrete pump, quantity of the operating hours and output of concrete.
g) Personal protective equipments like helmet, safety shoes, ear defenders (ear muff/ ear
plug), protective gloves and goggles, face mask/respiratory protector, etc. shall be
arranged by the contractor for all the workers working on concrete pump.
h) Concrete pump shall have suitable pressure relief valve, set at a predetermined
pressure level, in order to ensure safety of the workers as well as the pump.

5.5.7.7 Tools:
5.4.7.7.1 Pneumatic Tools:
The hose of the compressed air shall not be directed towards a person’s body.
Compressed air shall not be used for cleaning of dust on the clothes of the workers. The
compressed air line shall not be bent to stop the flow of air. This may cause building of
pressure resulting in bursting of pipe and injury to the person. The operator shall use
earmuffs on regular basis. The person cleaning certain area with compressed air shall be
given safety goggles, dust respirators and ear plugs. Other workers shall not be present in
the area which is being cleaned.
5.4.7.7.2 Abrasive Tools:
All machines, hand tools, etc. shall be test driven and necessary earthing shall be checked
before actual use. All moving parts of mills, mixers and disintegrators shall have secure
guards to avoid injury to workers. Contractor shall provide protective equipment to
workers involving in crushing, grinding or pulverizing operations and all the machines
shall be covered overall with hard material to keep them clean.
a) Drills: All the pneumatic drills shall be equipped with the additional lateral handles to
avoid accidents wherein the back twisting torque exceeds 15 Nm. Compressed air
hoses shall be suitably covered or hung from the ceiling.
b) Saws: The contractor shall ensure that all the built‐in safety devices of the pneumatic
saws such as adjustable riving knife, guard hood, replaceable blade aperture insert,
push stick and start/stop switch shall not be tampered by the workers during
operations. The contractor shall provide standard PPEs such as ear plugs or earmuffs
as the noise level during operations of saws may exceed 90 dB.
c) Grinding machines: The contractor shall use correct type of wheel depending on type
of material to be ground such as separate wheel for concrete and steel surfaces, etc.
The expiry date written on the wheel shall be referred before use. The RPM of the
wheel shall match with that of the grinding machine. The wheel may get chipped or
cracked in transportation or in storage. In order to check this defect, the wheel shall
be held loosely on a finger through the arbor hole and tapped lightly with a wooden
hammer. The grinding machine shall have proper earthing, guards, etc. and the
operator shall use all necessary PPEs like hand gloves, goggles, ear plugs, dust
respirators, etc.
d) Pneumatic Tools Safety: The contractor shall check all the rotating tools with the
Tachometer for proper operating speed before accessories are attached. The
 Contractor shall operate all the grinding wheels under or inside the guards (except
cone shaped wheels and small mounted points). The diameter of the wheel arbors
shall match that of the grinding wheels. The wheel washer (blotter) and collar shall
grip the wheel firmly and the two shall never be of different diameters. The nut which
holds the wheel on the arbor and the washer (blotter) against the wheel shall be of
ample size and strength. The contractor shall follow the manufacturer’s charts about
the applications and speed of the various types of the grinding wheels.
e) Hand Tools:
i) Impact Tools: The contractor shall use precision grip for the most commonly
used impact tool, hammer for light work. For safe operations, the hammer shall
have a straight cylindrical handle of 24 to 40 mm caliber with a maximum length
of 600 mm and maximum head weight of 6.5 to 7.5 kg. Hammers shall be
maintained such that cracked or weak handles are replaced and heads are in good
condition and firmly secured to an undamaged handle.
ii) Cutting Tools: The contractor shall ensure that various cutting tools like axes,
chisels and shovels, etc. are made up of material with adequate strength. The
contractor shall ensure that wooden handles are to be moist before use during
summer. Proper PPEs like hand gloves, ear plugs, goggles, dust respirators, etc.
shall be provided to the worker as per the need of the work.

5.5.8 Structural Steel Fabrication:

5.5.8.1 Welding and Gas Cutting: Welding and gas cutting operations shall be done only
by qualified and authorized persons and as per IS: 818‐1968 (Reaffirmed in 2008). No hot
job shall be done without approved work permit.

a) Welding and gas cutting shall not be carried out in places where flammable/any
materials such as combustible/flammable chemicals, dyes, hessian cloth, wooden
pieces, cylinders, etc. are kept within 10 m from the spot of fabrication or gas
cutting.
b) Gas cylinders:
i) General precautions:
‐ Cylinders together with their valves and other fittings and identification
colors shall be maintained in good condition.
‐ No lubricant shall be used in any fittings of the cylinders.
‐ No cylinder shall be subjected to any heat treatment or exposed to a high
temperature or to the sun or stored with flammable or explosive material.
‐ Every cylinder containing compressed gas shall have its valve securely closed
so as to prevent leakage. Valves fitted to the cylinders containing LPG and
highly toxic gases shall be provided with security nut on the outlet to act as a
secondary means of safeguard against leakage of gas.
‐ If the leak in the valve cannot be rectified by tightening the gland‐nut or the
spindle, the cylinder shall be removed to an open space where it is least
dangerous to life and property and the Filler shall be informed.
ii) Handling and use:
‐ Cylinders shall be adequately supported during handling.
‐ Trolleys and cradles of adequate strength shall, as far as possible, be used
when moving the cylinders.
‐ The cylinders shall be handled carefully and not be allowed to fall on one
another or subjected to any undue shock.
‐ Sliding, dropping or playing with cylinders is prohibited.
‐ LPG cylinders and cylinders containing liquefied gas shall always be kept in
upright position and be so placed that they cannot be knocked over.
‐ Cylinders used in horizontal position shall be so secured that they do not roll.
‐ Open flames, lights, lighting of fires, welding and smoking shall be prohibited
in close proximity of any cylinder containing flammable gases except those in
use for welding, cutting or heating.
iii) Storage of cylinders:
‐ Cylinders shall be stored in cool, dry, well ventilated place under cover, away
from boilers, open flames, steam pipes or any potential sources of heat and
such place shall be easily accessible.
‐ The storage room or shed shall be of fire‐resistant construction.
‐ Thin‐walled cylinders such as LPG and cylinders of dissolved gas shall not be
stacked in horizontal position.
‐ Cylinders containing flammable and toxic gases shall be kept separated from
each other and from cylinders containing other types of gases by an adequate
distance or by suitable partition wall.
‐ Cylinders shall not be stored under conditions that will cause them to corrode.
‐ Cylinders shall not be stored with any combustible materials.
‐ Empty cylinders shall be segregated from filled ones and care shall be taken
that the valves are tightly shut.
‐ Specificity of gas cylinders: Gas cylinders designed and approved for filling a
particular gas should not be used for filling with any other gas without specific
approval from the Chief Controller of Explosives.
iv) Transport of cylinders:
‐ Cylinders filled with any compressed gas shall not be transported by bicycle or
any other two‐wheeled mechanically propelled vehicle.
‐ Cylinders shall be so transported as not to project in the horizontal plane
beyond the sides or ends of the vehicle by which they are transported.
‐ Cylinders shall be adequately secured to prevent their falling off the vehicle
and being subjected to rough handling, excessive shocks or local stresses.
 v) Restrictions on transport of cylinders:
‐ Cylinders containing flammable gases shall not be transported along with
cylinders containing any other type of compressed gas.
‐ Cylinders containing toxic or corrosive gases shall not be transported along with
food‐stuff.
vi) Loading and unloading of cylinders for transport: No lifting magnet shall be
used in loading or unloading of cylinders filled with compressed gas. When any
such operation is carried out by means of a crane or fork lift truck, a proper cradle
with chains or wire rope slings shall be used.
vii) Protection of valves: The valves of compressed gas cylinders should be
protected against damage during transport.
viii) Notice of accident: Notice of an accident involving compressed gas cylinder
should be given to the Chief Controller of Explosives, by an express telegram,
followed by a letter within 24 hours giving particulars of the occurrence and to the
Officer‐in‐Charge of the nearest Police Station.
ix) Condemning of Cylinders: Any cylinder which does not pass the periodical test
or loses over 5% of its tare weight or found to be defective should be destroyed.
c) Barrier screens shall be erected to protect other persons from harmful rays and
sparks from the work. When welding or gas cutting is carried out in elevated
positions, precautions like providing metal sheet, etc. shall be taken to prevent
sparks or hot molten metal falling on persons or flammable materials below.
d) Adequate ventilation shall be provided for easy dispersion of gas while welding,
brazing and cutting in confined space.
e) Suitable type of protective clothing consisting of fire resistant gauntlet gloves,
boots and aprons shall be provided to workers to protect from heat and hot
molten metal splashes. Welding shields with filter glasses of appropriate shade
shall be worn as face protection against UV & IR rays.
f) Welding and gas cutting shall not be carried out by standing on drums, barrels,
tanks or other containers.
g) Appropriate type fire extinguisher and fire bucket shall be available near the
location of welding operations.
h) Contractor’s safety officer shall ensure at least half an hour fire watch after the
hot work is over.

5.5.8.2 Electric Arc Welding: For Electric Arc welding the following additional safety
precautions shall be taken:
i) All power connections shall be routed through ELCB of proper rating and
machine connections shall be through MCB. Double earthing shall be provided to
the welding machine. A provision of a separate return path shall be ensured.
ii) The cable to be used shall be of adequate capacity corresponding to output of
the welding transformer / generator and shall be routed through dry isolated
path. Welding cable terminals shall be provided with lugs and connected properly.
 Proper insulation of cable with insulation tape of approved quality shall be
ensured and only double insulated cable shall be used. Extension of welding
cables shall be done using standard connectors.
iii) Pipe lines carrying flammables shall not be used as part of earth conductor, but
a separate earth conductor shall be connected to the machine directly from the
job. Painting and Dye Penetration testing shall not be done near electric arc
welding.
iv) Personal contact with the electrode or other live parts of electric welding
equipment shall be avoided. Wires and cables shall not be hung from any metal
hook.
v) Accidental contact of electrodes with ground shall be prevented.
vi) The welding cables shall not be allowed to get entangled with power cables. It
shall be ensured that the cables are not damaged by movement of materials.
Dragging and coiling of cable shall be avoided.
vii) For Dye Penetration test, necessary care shall be taken so that there is no hot
job going on nearby. Place of the test shall be well ventilated.

5.5.8.3 Grinding:
i) All portable grinders shall be used only with their wheel guards in position to reduce the
danger from flying fragments should the wheel break during the use.
ii) Grinding wheels of specified diameter only shall be used on a grinder portable or
pedestal in order not to exceed the prescribed peripheral speed.
iii) Goggles shall be worn during grinding operation.
iv) All safety procedures as mentioned in 5.4.7.7.2 shall also be followed for grinding
activity.
v) Safety provisions for grinding activity as per IS: 1991‐1987 (Part 1‐10) (Reaffirmed
in 2002) shall be followed.

5.5.8.4 Erection: Only trained operators and workers shall be engaged for the erection of
structural fabricated members. For erection by mechanical means, the safety procedures as
mentioned in 5.4.7.2 and 5.4.7.3 shall be followed in addition to the following guidelines:
a) The heavy materials shall not be manually handled. They shall be handled and shifted
by mechanical means like crane, hydra, trolley, etc. of adequate capacity.
b) All mechanical transport devices and erection equipment shall be operated with the
assistance of a helper / supervisor exclusively for proper signaling.
c) While erecting fabricated members, suitable guy rope arrangement shall be made to
avoid sudden toppling of derrick.
d) Chain pulley block, D‐shackles and wire ropes (lifting appliances) shall be have rated
capacity at least 2.0 times more than the maximum desired load to be lifted. Hooks, jigs
and fixtures used shall be marked with their capacities.
e) Two or more slings shall be used for lifting the loads and they shall be tied as per the
centre of gravity of the load to be lifted.
5.5.9 Electrical Safety: Guide lines for providing temporary power supply at the site and general
safety procedures for using electricity are given as under. Following safety requirements shall be
complied with before the Contractor uses the power supply.
The Contractor shall submit a list of licensed electrical staff to be posted at site. It shall be
the responsibility of the Contractor to provide and maintain complete installation on the load
side of the supply point with regard to the safety requirements at site. All cabling and installation
shall comply with the appropriate statutory requirements given below and shall be subject to
approval of the Departmental Engineer‐in‐charge/ Electrical Engineer.
a) The Electricity Act, 1910 (as amended in 2003)
b) Electricity (Supply) Act, 1948
c) Indian Electricity Rules, 1956 (as amended in 2005)
d) National Electric Code 1985 (as amended in 2005)
e) Other relevant rules of Local Bodies and Electricity Boards
5.5.9.1 After installation of the electrical power wiring works by the contractor, form of
completion certificate as per IS: 732 – 1989 (Reaffirmed in 2005) (Form SGCW – 1 – Annexure
11) shall be submitted by the contractor duly signed by the authorized valid licensed electrical
contractor and /or supervisor along with one copy of the contractor's license and/or competency
certificate of supervisor issued by the Electricity Board/Government Electricity Organizations as
per the enclosure. The power supply shall be regulated as per the terms and conditions of the
supply of the respective electricity boards.
(a) For purposes of electrical load and power planning by the electrical section, the
contractor shall furnish along with the tender, the estimated load requirement of electric
power for the execution of the contract works in terms of maximum Kilo Watt or KVA
demand during various periods/months of the contract period along with the details of
the construction electrical equipment/machinery with their individual load details and
location/locations of power supply required for availing temporary electric power supply
in the standard preform enclosed (Form SGCW‐ 2 – Annexure 12).
(b) The electric power supply will be generally made available at one point in the works
site of the contractor by the department.
(c) Where distribution boards are located at different places the Contractor shall submit
schematic drawing indicating all details like size of wires, overhead or cable feeders,
earthing, etc. The position and location of all equipment and switches shall be given.
(d) The Contractor shall make his own arrangements for main earth electrode and tapping
thereof. The existing earth points available at site can be used at the discretion of the
Departmental Electrical Engineer with prior permission. Method of earthing, installation
and earth testing results shall conform to relevant IS Specifications [IS: 3043 – 1987
(Reaffirmed in 2001)]. All three phase equipment shall be provided with double earthing.
All light fixtures and portable equipment shall be effectively earthed to main earthing.
(e) All earth terminals shall be visible. No gas pipes and water pipes shall be used for
earth connection. Neutral conductor shall not be treated as earth wire.
 (f) The Contractor shall not connect any additional load without prior permission of
Departmental Electrical Engineer. For obtaining additional power required, test reports of
the tests mentioned in (d) of Form SGCW ‐ 1 (Refer Annexure – 11) shall be submitted.
(g) Joints in earthing conductors shall be avoided. Loop earthing of equipment shall not
be allowed. However tapings from an earth bus may be done.
(h) The entire installation shall be subjected to the following tests before energizing of
installation including portable equipment:
i) Insulation resistance test
ii) Polarity test of switches
iii) Earth continuity test
iv) Earth electrode resistance.
The test procedures and their results shall conform to relevant IS specifications. The Contractor
shall submit a test report for his complete installation every 2 months and also every time after
rectifying any faulty section. One such test report for the complete installation shall be submitted
before onset of monsoon.
The following are provided for general guidance of the Contractor and shall be read as specific
requirement, in addition to complying with Indian Electricity Act, Indian Electricity Rules and IS
Specifications.

5.5.9.2 Installation:
a) Only persons having valid wireman's license/competency certificate shall be
employed for carrying out electrical work and repair of electrical equipment,
installation and maintenance at site. The job shall be supervised by a qualified
licensed supervisor.
b) Electrical equipment and installations shall be installed and maintained as to
prevent danger from contact with live conductors and to prevent fires originating
from electrical causes like short circuits, overheating, etc. Installation shall not
cause any hindrance to movement of men and materials.
c) Materials for all electrical equipment shall be selected with regard to working
voltage, load and working environment. Such equipment shall conform to the
relevant standards.
d) The minimum clearance to be maintained for all overhead lines along roads and
across roads shall be 6.10m ( minimum) as per the Rules 77‐80 of Indian Electricity
Rules, 1956 (Amended in 2005).
e) Grounding conductor of wiring system shall be of copper or other corrosion
resistant material. An extra grounding connection shall be made in
appliances/equipment where chance of electric shock is high.
f) Electric fuses and/or circuit breakers installed in equipment circuits for short
circuit protection shall be of proper rating. It is also recommended that high
rupturing capacity (HRC) fuses shall be used in all circuits. As Earth Leakage Circuit
Breaker shall be provided for all 3 Phase supply irrespective of kilo watt rating and
for all single phase supply equal to or exceeding 5 Kilo Watt rating.
g) Wires and cables shall be adequately supported and an approved method of fixing
shall be adopted. Loose hanging of wires & cables shall be avoided. Lighting and
power circuits shall be kept distinct and separate.
h) Reinforcement rods or any metallic part of structure shall not be used for
supporting wires and cables, fixtures, equipment, earthing, etc.
i) All cables and wires shall be adequately protected against mechanical damages. In
case the cable is required to be laid underground, it shall be adequately protected
by covering the same with bricks, Plain Cement Concrete (PCC) tile or any other
approved means.
j) All armored cables shall be properly terminated by using suitable cable glands.
Multi‐stranded conductor cables shall be connected by using cable lugs/ sockets.
Cable lugs shall preferably be crimped. They shall be of proper size and shall
correspond to the current rating and size of the cable. Twisted connections shall
not be allowed.
k) All cable glands, armoring and sheathing of electric cables, metal circuits and their
fittings, metallic fittings and other non‐current carrying parts of electrical
equipment and apparatus shall be effectively grounded.
l) All the Distribution Boards, Switch Fuse units, Bus bar chambers, ducts, cubicles
etc. shall have Mild Steel enclosures and shall be dust, vermin and water proof.
The Distribution Boards switches etc. shall be so fixed that they shall be easily
accessible. Changes shall be done only after the approval of the Departmental
Electrical Engineer.
m) The Contractor shall provide proper enclosures/covers of approved size and shape
for protection of the entire switch board, equipment etc. against rain. Exposed live
parts of all electrical circuits and equipment shall be enclosed permanently. Crane
trolley wires and other conductors which cannot be completely insulated shall be
placed such that they are inaccessible under normal working conditions.
n) Iron clad industrial type plug outlets are preferred for additional safety.
o) Open type Distribution Boards (DBs) shall be placed only in dry and ventilated
rooms; they shall not be placed in the vicinity of storage batteries or otherwise
exposed to chemical fumes.
p) Isolating switches shall be provided close to equipment for easy disconnection of
electrical equipment or conductors from the source of supply when repair or
maintenance work has to be done on them.
q) In front of distribution boards (DBs) a clear space of 1.0 m shall be maintained in
order to have easy access during an emergency. Pathway to DBs shall be
maintained free from any obstacles. If there are any attachment/base connection
at the back side of the switch board, the space, if any behind the switch board
shall be either less than 20cm or more than 75cm in width, measured form the
farthest outstanding part of any attachment or conductor. If the space behind the
switch board exceeds 75cm in width, there shall be a passage way from either end
of switch board clear to a height of 180 cm.
 r) As far as possible electrical switches shall be excluded from a place where there is
danger of explosion. All electrical equipment such as motors, switches and lighting
fittings installed in work room where there is possibility of explosion hazard shall
be explosion proof.
s) All connections to lighting fixtures, starters or other power supplies shall be
provided with PVC insulated, PVC sheathed twin/three/four core wires to have
better mechanical protection for preventing possible damage to equipment or
injury to personnel. Taped joints shall not be allowed and the connections may be
made in looping system. Electric starter of motors, switches shall not be mounted
on wooden boards. Only sheet steel mounting or iron frame work shall be used.
t) All the lighting fixtures and lamp holders shall be of good quality and in good
condition. Badly repaired or broken holders, etc. shall not be used.
u) Only PVC insulated and PVC sheathed wires or armored PVC insulated and
sheathed cables shall be used for external power supply connections of temporary
nature. Weather proof rubber wires shall not be used for any temporary power
supply connections. Taped joints in the wires shall not be used.
v) Lamps used for illumination and testing purpose shall have cover or guard to
protect them from accidental breakages. Only 24 Volt supply system shall be used
for hand lamps etc, while working inside metallic tanks or conducting vessels.
w) After installation of new electric system and or other extensive alterations to
existing installations, thorough inspection shall be made by Departmental
Electrical Engineer before the new system or new extension is put in use.

5.5.9.3 Operation & Maintenance:

a) All persons who work with electrical installation/equipment shall be aware of the
electrical hazards, use of protective devices and safe operational procedures. At
least two persons in a shift shall be given training in firefighting, first aid and
artificial resuscitation techniques. First Aid treatment of electrical shock shall be
displayed at First Aid Centre.
b) The supervisor shall instruct the workers for the proper procedure, specify and
enforce the use of necessary protective equipment such as adequately insulated
pliers, screw drivers, fuse pullers, testing lamps and similar hand tools. Only
wooden ladders shall be used to reach the heights in electrical work.
c) No material or earth work shall be allowed to be dumped below or in the vicinity
of the bare overhead line conductors. Minimum clearance of 6.10m shall be
maintained.
d) Separate work permits shall be issued in accordance with IS: 5216‐1982
(Reaffirmed in 2010) working on the same system which shall be returned after
the completion of the work to Safety Officer and no system shall be restored
without the clearance of Safety Officer.
Before any maintenance work is commenced on electrical
installations/equipment, the circuits shall be de‐energized and ascertained to be
 Dead by positive test with an approved voltage testing device. Prior to attempting
repairs on the equipment Switch off, Isolate, Discharge and Earth (SIDE) Rule
should be strictly followed. Switches shall be tagged or the fuse holders
withdrawn before starting the work. During electrical works, minimum two
persons shall be available. Adequate precautions shall be taken in two important
aspects viz.
(i) That there shall be no danger from any adjacent live parts and
(ii) That there shall be no chances of re‐energizing of the equipments on
which the persons are working.
f) While working on or near a circuit, whenever possible the use of one hand may be
practiced even though the circuit is supposed to be dead. The other hand may
preferably be kept in pocket.
g) When it is necessary to touch electrical equipment (for example when checking
for overload of motors) back of the hand may be used. Thus, if accidental shock
were to cause muscular contractions, one would not 'freeze' to the conductor.
h) Operation of electrical equipment shall be avoided when standing on wet floor or
when hands are wet.
i) Before blown fuses are replaced, the circuit shall be locked out and an
investigation shall be made for the cause of the short circuit or overload.
j) When two persons are working within reach of each other, they shall never work
on different phases of the supply.
k) When structural repairs, modification or painting works are to be undertaken,
appropriate measures shall be taken for the protection of persons whose work
may bring them into the proximity of live equipment/circuit.
l) It shall be ensured that the insulation and wire size of extension cords are
adequate for the voltage and current rating.
m) While tapping electricity from the socket, plug top must be used. It shall be
ensured that no extension boards are over loaded while tapping. Only standard
three pin plugs shall be used for tapping electricity. Broken sockets/plugs shall be
replaced immediately with good ones. Only joint free cables shall be used for
connecting equipment/apparatus.
n) Floors shall be kept free from trailing electrical cables to avoid tripping hazard.
o) Power supply to all the machines and lighting fixtures shall be switched off when
not in use.
p) Temporary electrical connections shall be removed as soon as the stipulated work
is over. After completion of the works, the contractor shall dismantle the
distribution boards and the other facilities he may have erected.
q) Unauthorized tapping of power by others from distribution boards under the
control of the contractor shall be prohibited at all circumstances.
r) Safety work permits shall be used for switching off the main feeder and
equipment by the contractor.
 s) "MEN ON LINE", "DO NOT SWITCH ON", "DANGER" or "CAUTION" boards as
applicable shall be used during maintenance works on the electrical equipment.
t) Power tapping of electrical equipment shall as near as possible of the equipment.
u) During maintenance at height, proper access by ladder shall be adopted.
5.5.9.4 Portable Electrical Equipment:
a) Portable electrical equipment shall be regularly examined, tested and maintained
to ensure that the equipment and its leads are in good order. Register shall be
maintained for inspection recording the testing dates and results of the
equipments. The insulation and winding resistance of the portable electrical
equipment shall be checked at least once in a month and report shall be
submitted for all such machines. A typical format for testing portable and other
electrically operated equipment is enclosed as Annexure‐15.
b) All portable appliances shall be provided with three core cables and three pin
plugs. The third pin of the plug shall invariably be earthed. It shall be ensured that
the metal part of the equipment shall be effectively earthed.
c) All connections to portable equipment or machines from the panel/distribution
board/extension board shall be taken using 3 core double insulated PVC flexible
copper wire in one length. No joints shall be allowed in this flexible wire. In case,
single length of wire is not sufficient for a particular location then the supply can
be tapped by providing another extension board comprising of switch and socket.
Isolation switch shall be made available as close as possible to the equipment.
d) Flexible cables for portable lamps, tools, and apparatus shall be regularly
examined, tested periodically and maintained to ensure safety and protected
against mechanical damages.

5.5.10 Fire Safety: The contractor shall take all necessary precautions to prevent outbreak of
fires at the construction site. Adequate provisions shall be made to extinguish fires should they
still break out.
(a) Quantities of combustible materials like timber, bamboos, coal, paints, etc. shall
be the minimum required in order to avoid unnecessary accumulation of
combustibles at site.
(b) Containers of paints, thinners and allied materials shall be stored in a separate
room which shall be well ventilated and free from excessive heat, sparks, flame or
direct rays of the sun. The containers of paint shall be kept covered or properly
fitted with lid and shall not be kept open except while using.
(c) Fire extinguishers suitable for the different classes of fire such as Class A, B, C & D
as per IS: 2190‐1992 (Reaffirmed in 2010) shall be made available at the
appropriate places in the construction site. The date of last maintenance of fire
extinguisher shall be displayed properly on the same by using maintenance tag.
The fire extinguishers shall be sent for maintenance/refilling at least once in 6
months or whenever exhausted. The safety officer shall inspect the condition of
the plunger, safety pin, switch grip, hose tube, etc. at least once in a month and
 Report shall be submitted to the departmental representative as per the format
enclosed as Annexure 14.
(d) Adequate number of contractor’s workmen and supervisors shall be given training
in firefighting and extinguishing methods.
(e) The safety officer of the contractor shall plan for site evacuation in fire emergency
in order to facilitate to easy and safe exits for entire site work force and
supervisory staff. He shall identify and train the designated staff or supervisor for
specific role in site evacuation plan.
(f) The telephone number of the nearest fire station shall be displayed at suitable
locations (near telephone, main entrance of the site, first aid centre, stores, etc.)
in bold distinct font.

5.5.11 Housekeeping:
5.5.11.1 The Contractor shall promote and upkeep the practice of good housekeeping
throughout the contact period in order to create a safe and hygienic working
environment at site. The contractor shall maintain a separate housekeeping team of
workers and supervisors who shall maintain the hygienic conditions at site. He shall at all
times, keep his work spot, site office, labour toilets and surroundings and roads clean and
tidy from rubbish, scrap, surplus materials and unwanted materials, tools and equipment.
The contractor shall follow the recommendation of IS: 4082‐1996 (Reaffirmed in 2003) for
stacking and storage of construction materials and components at site.
5.5.11.2 Welding and other electrical cables shall be so routed as to allow safe traffic by
all concerned. Electrical cables shall not trail on the ground and they shall be raised above
ground with the help of posts, etc.
5.5.11.3 The plan of temporary structures shall be such that they do not hamper easy
movement of worker and vehicles. No materials on any of the sites of work shall be so
stacked or placed as to cause inconvenience to any person or the public. The Engineer‐in
charge may require the contractor to remove any materials which are considered to be of
danger or cause inconvenience to the public. If necessary, the Engineer‐in‐charge may
cause them to be removed at the contractor's cost.
5.5.11.4 After the completion of the work, the contractor shall have removed from the
work premises all scaffoldings, surplus materials, scrap, rubbish and all temporary
structures, huts and sanitary arrangements used/installed for his workmen at site. The
contractor shall stack all undesirable materials and debris to the designated area at his
own cost, as directed by Engineer‐in‐charge.
5.5.11.5 The Engineer‐in‐charge has the right to stop work if the Contractor fails to
improve upon the housekeeping after having been notified.
5.5.11.6 The contractor shall instruct workmen to keep all accesses clear from any
obstruction and unwanted material for free and safe movement of the workers and staffs
including departmental staffs. He shall provide tool box and safe means for carrying tools
(for working at height) to all his workers so that tools and tackles are kept in proper place.
 The working area shall be free from wastes like nails, binding wires, nuts & bolts, used
plastics, etc. so that they do not cause injury to others.

5.4.12. Safe access to workplace:

5.4.12.1 Adequate and safe means of access and exit shall be provided for all work places,
at all elevations. Ladders shall be always used for approaching high elevations.
5.4.12.2 Suitable scaffolds shall be provided for workmen for all works that cannot safely
be done from the ground, or from solid construction except such short duration work as
can be done safely from ladders. Safety procedures for ladder shall be as per 5.4.6.3
above.
5.4.12.3 Safety procedures for Scaffolding and working platform shall be as per 5.4.6
above.
5.4.12.4 All access to the work place shall be well guarded viz. stairs, ramps, etc. and shall
be well illuminated as per the requirement of clause 15.8 (Illumination Guidelines) of SP:
70‐2001. The access shall not have any water logging; they shall be levelled and dry so
that people do not slip. Sign boards, written in language understood by majority of the
workers, and exit signs shall be displayed at suitable location for easy identification. The
steps of the stair shall be periodically cleaned for any accumulation of debris, dust, etc.

5.4.13 Common Hazards:

5.4.13.1 Barricading and Sign Boards: All work areas around excavated pits, trenches,
openings, scaffolding, vehicle movement areas, etc. shall be well cordoned / barricaded
with the help of railing, safety tapes (photo luminescent), etc. Photo luminescent sign
boards and warnings shall be displayed at required locations and they shall be clearly
visible from a distance even at low or no illumination.
5.4.13.2 Noise: Suitable ear protection (ear muff) shall be provided to the workers, who
are exposed to high noise levels (85dBA and above), e.g. concrete pump operator,
vibrator operator, batching plant operator, air compressor operator, grinding machine
operator, breaking rocks with pavement breaker, cutting of marble/granite, etc. The
exposure duration in case of these workers shall be restricted to the stipulation of Table‐1
of Schedule‐XI, Rule‐88 of AEFR, 1996. Other workers and staff who are in the close
vicinity of high noise level such as unskilled worker engaged in concreting works, etc. shall
be provided with ear plugs.
5.4.13.3 Area Illumination: Adequate lighting facilities such as flood lights, halogen
lamps, hand lights and area lighting shall be provided by the contractor at the site of
work, storage area of materials and equipment and temporary access roads within his
working area. The area illumination shall be such that it promotes work and safety for all
workers at site and creates a pleasing environment at work site. The contractor shall
obtain written approval of the Engineer‐in‐charge to the lighting scheme and place of
tapping prior to its installation. The intensity of illumination shall depend on the nature of
work and the same shall be planned by the contractor in advance based on the
recommendations of Hand Book on Functional Requirements of Industrial Buildings
 (Lighting & Ventilation: SP32‐1986). However, a minimum illumination as per the task
performed shall be maintained at site; which can be augmented based on nature of work
from time to time.
5.4.13.4 Dust and fumes: Confined areas like basement, bunkers, etc. shall be under
forced ventilation (using blowers) for at least 3‐7 air changes per hour depending on
presence of dust and fumes generated from grinding, gas cutting, welding, etc. Adequate
measure like dust extractor/arresters shall be available for use to prevent spread of dust
to nearby areas during open area operations. Workers shall be rested for sufficient time
after every one hour of continuous working in dust. The same worker shall not be
engaged for grinding for many days continuously and they shall be engaged/kept on job
rotation. All necessary PPEs like dust respirators, safety goggles, hand gloves, ear plugs,
protective clothes, etc. shall be provided. Any illness due to continuous work in dust or
fume shall be immediately reported to the First Aid Centre.

5.5 Personal Protective Equipment:

All necessary personal protective equipment (PPE) shall be provided by the contractor at
his own cost, for his workers, supervisors, staffs and visitor/visiting staffs. All PPEs shall
conform to relevant IS code / ASTM / BS or any other international code of practice as
given under. The contractor shall make available all type of personal protective
equipment for use of workers, supervisors and visitors at site as considered necessary by
the Engineer‐in‐charge and they shall be maintained in a condition suitable for immediate
use. Also the contractor shall take adequate steps to ensure proper use of equipment by
those concerned.
Safety Helmet: IS: 2925‐1984 (Reaffirmed 2000)
Safety Goggles: IS: 5983‐1980 (Reaffirmed 2002) or EN 166:2001
Full body harness safety belt: IS: 3521‐1999
Ear Muff / Ear Plug: IS: 6996‐1973 (Reaffirmed 1998) or EN 352‐1:2002
And EN 352‐2:2002 or
Face shield: IS: 8521 (Part II) – 1977 (Reaffirmed 2002)
IS: 8521 (Part I) –1994 (Reaffirmed 2002) or EN 175F
Fall arrestor: EN 353‐2:2002
Respirators: IS: 15321 – 2003, IS: 15322 – 2003
Safety shoes: IS: 15298 – 2002
Hand gloves: IS: 4770 – 1991 (Reaffirmed 2001)

(a) All persons employed or supervising at and / or visiting the construction site shall use
safety helmets. The color coding of helmets may be adopted by the contractor as per
site requirement. The contractor shall provide safety shoes for all his workers,
supervisors, staffs and visitor/visiting staffs.
(b) Workers employed on mixing asphaltic materials, concrete, cement and mortars shall
use PPEs such as protective goggles, protective foot wears, respirators and hand gloves,
etc.
 (c) Persons engaged in welding and gas cutting works shall use appropriate welding face
shields, leather hand gloves and protective clothes. The persons who assist the welders
shall use appropriate goggles.
(d) Workers breaking rock, grinding and chipping shall use protective goggles, dust
respirators, ear muffs/ear plugs, etc. In addition, leather hand gloves shall be used where
there is no possibility of entanglement with rotating parts. During work, other workers
should maintain the safe distance.
(e) Persons working at height above ground level or floor and exposed to risk of falling
down shall use full harness safety belts, kinetic shock absorbers, fall arrestor, life lines,
and grab ropes. The working platform and access shall be protected by cages, guard
railings, etc. The area beneath shall be protected by safety net of adequate strength (as
per IS: 11057 – 1984) fastened to substantial supports.
(f) Wherever two‐wheelers are allowed, motorcycle and scooter drivers and their pillion
riders shall wear crash helmets inside the Project/Plant sites. Safety helmets shall not be
replaced with crash helmets and vice‐versa.
(g) When workers are employed in sewers, septic tanks and inside man‐holes which are in
use, the contractor shall ensure that the manholes are opened and are adequately
ventilated. After it has been well‐ventilated, the atmosphere inside the space shall be
checked for the presence of any explosive mixture, toxic gas or oxygen deficiency. The
workers shall be allowed to get into the man‐holes under safe working environment only.
The man‐holes opened shall be cordoned off with suitable railing and provided with
warning signals or caution boards to prevent accidents. There shall be proper illumination
in the night. All safety measures for working in confined space as given in the Factory Act
shall be ensured. In case of forced ventilation, battery backup for ventilation and
measures to rescue workers shall be ensured.

5.6 General Health Management at site:

The contractor shall arrange adequate facilities for medical aid and treatment for his staff
and workers engaged on the work site and visiting staffs including the first‐aid facilities at
the project site.

5.6.1 General:
5.6.1.1 General medical examination: The contractor shall follow the guidelines of Rule
81 (IV), Schedule VII of BOCW Central Rules, 1998 for periodicity of medical examination
of building workers.
5.6.1.2 High noise level: The contractor shall arrange for audiometry examination for
workers exposed to high noise level as per Chapter IX, Rule 88, Schedule XI, Sub‐Rule 3 (f)
(ii) Of AEFR, 1996.
5.6.1.3 High dust exposure: The contractor shall arrange for medical examination for
workers exposed to high dust level as per Chapter IX, Rule 88, Schedule IV, Sub‐Rule 9 of
AEFR, 1996.
5.6.1.4 Eye sight examination for crane operators, etc.: The contractor shall arrange for
medical examination for crane operators and other vehicle operators like operators of
material transportation/handling equipment, mechanical excavators, etc. as per Chapter
IV, Rule 55 of AEFR, 1996.

5.6.2 First Aid Facility:

The contractor shall ensure medical and first aid facility at site as per Rule 223 to 232,
Chapter XXIV, BOCW Central Rules, 1998 in order to facilitate immediate relief to the
injured person before shifting him to the nearest departmental dispensary or public
hospital. All the provisions of the above mentioned rules of BOCW Central Rules, 1998 viz.
medical examination of building workers, duties of medical attendant, occupational
health centre, ambulance room (first aid centre), ambulance van or safety vehicle, etc.
shall be arranged by the contractor at site.

5.6.3 Full‐time Medical Attendant:

First aid posts shall be established and be manned by a full‐time trained medical
attendant. The medical attendant shall have a degree of B.Sc. in Nursing or equivalent and
a minimum 5 years of working experience in any nursing home or general hospital. The
contractor shall submit his/her certificates and credentials to the department in advance
for approval before employing him/her at site. The duties of the medical attendant shall
be as given below:
(a) First‐aid care including emergency medical treatment
(b) Immunization services
(c) Medical records upkeep and maintenance
(d) Health education including advisory services on family planning, personal hygiene,
environmental sanitation and safety
(e) Referral services

5.6.4 First‐Aid Box, Medicines and Medical Equipment:

a) First‐aid box containing bandage, sterilized dressing, ruler bandage, triangular bandage,
crape bandage, dry gauge, and band aid, antiseptic such as savlon/Dettol, cotton wool,
plaster, scissors, and antiseptic creams shall be arranged by the contractor, at a readily
accessible place in work site. The quantities of the listed items shall conform to Schedule
III of BOCW Central Rules, 1998 (Refer Annexure‐8). These shall be maintained in good
order under the charge of Full‐time Medical Attendant or the Safety Officer or a
responsible person in absence of them.

b) The articles for ambulance room or first‐aid post with effective communication system
shall be arranged by the contractor as per Schedule IV of BOCW Central Rules, 1998. The
list is enclosed as per Annexure 9. The size of the room shall be adequate for proper
treatment of the injured persons and keeping the enlisted articles in an organized
manner. The room shall be well ventilated and well illuminated, preferably by natural
 Means. The contractor shall keep a refrigerator of approx. 150 liters capacity for proper
storage of injections and temperature sensitive medicines.

5.7 Hygiene at workplace:

The contractor shall ensure hygiene at work place as well as at the residing place for all
his workers and staff. He shall submit the plan of labour colony and labour toilet in
advance for approval of the Engineer‐ in ‐charge.
a) Labour Toilet and urinal: Latrines and urinals, as the case may be required to be
provided, shall be as specified below:
a. Every latrine shall be under cover and so partitioned off as to secure privacy
and shall have a proper door and fastenings.
b. i) Where both male and female building workers are employed, there shall be
displayed outside each block of latrines or urinals a notice containing therein
“For Men Only” or “For Women Only”, as the case may be written in the
language understood by the majority of such workers.
ii) Such notice also bear the figure of a man or of a woman, as the case may
be.
c. Where females are employed, there shall be at least one WC for every 25
females. There shall be at least one WC for every 25 males. If the number of
males exceeds 100, there shall be one latrine for every 25 males up to the first
100 males, and one for every 50 males thereafter. The W.C shall be cleaned at
least once in a week and maintained properly by the contractor throughout
the project duration. The privacy of the all workers shall be ensured by
providing partitions of suitable heights. Proper disposal of excreta by septic
tank and soak pit shall be made by the contractor. In no case, the excreta shall
be disposed off in any open drain, nallah, etc. which may cause outbreak of
disease or reduce the overall hygiene of the workplace. Urinals shall be
provided for the use of male workers and there shall be at least one urinal for
every 50 males and where the number of males employed exceeds 50, it shall
be sufficient if there is one urinal for every 50 males up to the first 500
employed, and one for every 100 thereafter.
b) Drinking water: contractor shall provide adequate number of water taps, water
purifiers and water coolers for the potable water supply for the staff and workers at
his own cost. However, the water connection will be given by the department based
on the contract condition.
c) The contractor shall apply pesticides and mosquito repellent at regular interval or
whenever required, by fogging machine, etc., in the labour colony and at work site at
his own cost.

6.1 MONITORING AND REPORTING:

The contractor shall monitor, measure and regularly evaluate compliance with applicable
legal requirements. He shall recognize the importance of monitoring and reporting of
Hazards associated with site activities. He shall instruct his safety officer and site
engineers to monitor the unsafe conditions and unsafe acts regularly in order to record
the observations so that remedial measures can be taken in time. The contractor shall
not neglect or underestimate the near‐misses occurred at site and shall establish a
procedure to record all such near‐misses since the lessons learnt from them can prevent
recurrence of such incidents in future. The contractor shall report any accident occurred
at site as per format of Injury Report for Contract/Casual Worker (Refer Annexure 13). He
shall make available all the legal documents and records (as mentioned in 6.2 below)
related to safety for internal as well as external audits from time to time.

6.2 Walk‐through survey: The Safety Officer and site engineers shall carry out a walk
through survey every morning at site in order to monitor any unsafe conditions and
unsafe acts. This measure reduces the hazards in site activities and creates a safe
working environment at site. The safety officer and site engineers shall record any
observation of unsafe condition / act in the observation register immediately and the
corrective action to be taken along with the name of person responsible for the same.
The safety officer shall make a review visit to the place of observation, during next day’s
walk through survey, to review whether the corrective actions are taken or not and shall
inform his higher authorities / departmental staff in case the corrective measures are not
taken. The standard format of Observation Register / Complaint Record is enclosed
herewith as Annexure 10.

6.3 Records: The contractor shall maintain all safety and first aid / medical related
records and registers in the safety office / first aid post at site and such records and
reports shall be made available during audits and whenever required. These records and
reports shall be updated by safety officer and / or medical attendant at site in
consultation with their superiors and departmental staff from time to time. A typical list
of records under good practices for compliance with legal requirements related to
environment, occupational health and safety is given below:

i. Safety Organization Chart

ii. Training Records like initial safety induction training, pep‐talk, etc.
iii. Record of site safety inspection, walk through survey and observation
register
iv. Accident investigation report
v. Record of Accidents, Near‐misses / dangerous occurrences
vi. Record of test and examination of equipment and structures (like scaffold
check list, etc.) as per statutes/codes/standards
vii. Safe Operating procedure for various site activities
viii. Record of work permits
ix. Record of monitoring flammable and explosive substances at work place
x. Records of maintaining and testing of firefighting equipment
 xi. Medical records of workers and staffs (separate register shall be
maintained for injury at work and for general ailments and medical check‐
up for height passes)
xii. Site emergency plans
xiii. Record of waste disposal
xiv. Housekeeping inspection record
xv. Minutes of Site Level Safety Committee meetings and monthly safety
reports
xvi. Record of modification carried out in construction equipment
xvii. Calibration and testing record
xviii. Record of previous audits
xix. Records of applicable legal requirements (Refer Annexure‐I)
xx. Tree plantation record, if any
xxi. Environment and hygiene management plan
xxii. General complaint register

6.4 Inspection and Safety Audit: The contractor shall arrange internal safety inspections
by safety organization, designated for the project, at least once in a month in order to
monitor the status of implementation and adherence to the safety procedures. The
project shall be subject to external audit by a team / committee headed by Chief Safety
Officer, Engineering Services Group, BARC at least once in a year. However, the
contractor shall be prepared for surprise inspections and audits by the department or any
third party authorised by the department.

7.1 TRAINING AND AWARENESS BUILDING PROGRAMME:

The contractor shall train and build up a general awareness in safety among the workers
and staffs as a continuous effort throughout the project duration. He shall develop and
nurture a good safety culture among the staff and workers for an incident free
completion of the project. The contractor shall arrange for celebration of National Safety
Day / Week on 4th March every year and shall plan for conducting various safety events,
competitions, etc. during this period. He shall identify good safety performers among
different trades of workers and staff and shall reward them for their performance so as to
motivate the others.

7.2 Safety Event Calendar:

The Safety Officer shall chalk out a safety event calendar for various safety events,
training programs, mock drills, demonstration, inspections and audit etc. and shall
intimate the concerned people in advance. The contractor shall submit a copy of safety
event calendar to the department at the onset of the project / in the month of January
every year. This calendar shall be displayed at the site safety office / first‐aid post and the
contractor shall ensure that these events are conducted as per schedule.
7.3 Safety Induction Training:
The contractor shall ensure that each and every new worker attends initial safety
induction training before reporting at respective place of work. The workers shall report
to the safety officer first for receiving safety induction training and after successful
completion of such training they shall report to respective site engineer. The safety
officer shall intimate the workers about the probable hazards related to the work and
shall explain and demonstrate the importance and use of PPEs to them. The medium of
instructions shall be chosen depending on the language understood by the majority of the
workers. He shall also explain to the workers the security restrictions to be followed
inside BARC premises. The duration of such induction training depends on the type of
worker and shall be decided by the Safety Officer in consultation with the department.

7.4 Pep talk, Tool‐box training:

Subsequent to the initial safety induction training, the Safety Officer shall also conduct
safety pep talks and tool box training for various teams of workers in regular interval at
site. He may identify the groups in advance and finalize the topic of pep talk and
schedule the pep talk accordingly so that it does not affect the working hours of the
group. He shall arrange pep talks / tool box training on work related topics like use of
various PPEs and tools, housekeeping, hot job, electrical works, etc. He shall solicit active
participation of workers in such tool box training by asking them to share their experience
with their fellow workers. Record of such pep talks and tool box training along with a list
of people trained shall be kept at safety office and such records shall be submitted along
with monthly safety report.

7.5 Signboards, Posters, Displays: The contractor shall display adequate numbers of
signboards (written/painted in photo‐luminescent paint) at various workplaces,
movement area of mechanical equipment, diesel store, scaffoldings, first aid post, etc. in
order to warn the workers and staff of probable hazards at work site. Such signboards
shall be written in the language understood by majority of the workers. The contractor
shall also arrange for display of posters as an awareness building programmer. He shall
have to maintain these signboards and posters in good condition throughout the contract
period and shall have to replace them periodically. Some of the important topics for
signboards are given as under for guidance; however, work specific sign boards can be
designed and displayed at site.

a) Use of proper Personal Protective Equipment (PPE) viz. Safety helmet, safety
shoes, safety belt, safety goggles, face shield, ear plug / ear muff, gloves, dust
respirators, etc.
b) No Smoking specially near diesel room, stores or near combustible materials
c) Moving parts of equipment viz. fly wheels of piling rigs, motors of pumps, etc.
d) Hot job and fabrication works viz. welding, gas cutting, grinding, etc.
e) Unsafe Scaffolding (wherever the scaffold is in unsafe condition)
f) Open Excavation / Openings in floors (especially near excavated pit, trenches, lift
well, stair well, etc.)
g) Electrical installations and high voltage equipment viz. welding transformers,
meter panels, fuse distribution boards, etc.
h) Dismantling / demolition work in progress
i) High noise level area especially near concrete pumps, demolition areas, etc.
j) Fragile roofs (where sheeting and roofing work is going on)
k) Vehicle movement areas, access roads, etc.
l) Fire extinguisher (class wise)
m) Emergency exit
8.1 REFERENCES:
 AERB Safety Guide for Works Contract
 Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Central Rules, 1998
 Atomic Energy Factories Rules, 1996
 Job Hazard Analysis Report for Construction of Common Facility Building (CFB)
Project, at North Site BARC
 Operation and Maintenance Manual of Mobile Tower Crane (MTC‐3625 of M/s
Action Construction Equipment Ltd.)
 Operation and Maintenance Manual of Batching Plant (CP30 of M/s Schwing
Stetter)
 Operation and Maintenance Manual of Concrete Pump (M/s Putzmeister)
 SP32:1986 (Hand Book on Functional Requirements of Industrial Buildings ‐
Lighting & Ventilation)
 SP53:1992 (Hand operated hand tools ‐ Safety code for the use, care and
protection)
 SP70:2001 (Handbook on Construction safety practices)
 IS: 732 – 1989 (Reaffirmed 2005) Code of Practice for Electrical Wiring Installations
 IS: 818‐1968 (Reaffirmed 2008) Code of Practice for Safety and Health
Requirements in Electric and Gas Welding and Cutting Operations.
 IS: 1991 ‐ 1987 (Part 1 to 10) (Reaffirmed 2002) Safety Requirements for the Use,
Care and Protection of Abrasive Grinding Wheels
 IS:2190‐1992 (Reaffirmed 2007) Selection, Installation and Maintenance of First‐
aid Fire Extinguishers ‐ Code of Practice
 IS: 3043 – 1987 (Reaffirmed 2001) Code of Practice for Earthing
 IS:3696‐1987 (Reaffirmed 2002) Safety Code for Scaffolds and Ladders (Part 1‐
Scaffolds)
 IS:3696‐1991 (Reaffirmed 2002) Safety Code for Scaffolds and Ladders (Part 2‐
Ladders)
 IS: 4082‐1996 (Reaffirmed 2003) Stacking and storage of construction materials
and components at site
 IS:4379‐1981(Reaffirmed 2007) Identification of the Contents of Industrial Gas
Cylinders
 IS: 5216‐1982 (Reaffirmed 2010) Recommendations on safety Procedure and
Practices in Electrical work; Part – I: General; Part – II: Life Saving Technique
 IS: 10302 – 1982 (Reaffirmed 2005) Unified Nomenclature for Workmen for Civil
Engineering
 IS: 11057 – 1984 Specification For Industrial Safety Nets
 Annexure 1

FORMAT FOR LEGAL REGISTER

Sl. Products, Legislation Date Validity Reference Person Frequency Reference Record to
No. Processes on OHS of Date of Responsible of to be
or Effect From Applicable for Reporting procedures submitted
Services to Chapter/ Compliance and to External
Sec./ Rule Monitoring Control agency
 Annexure 2

FORMAT FOR JOB HAZARD ANALYSIS REPORT

Sl. No. Activity / Sub‐activity Potential hazards Causes Precautions

recommended
 Annexure 3

FORMAT FOR WORK PERMIT

(To be filled in by contractor in quadruplicate)

Name of the work:

Name of the principal contractor:
W.P. No.: Date:
Work Permit valid from on to on
(Time) (Date) (Time)
(Date) Name of the Site Engineer seeking
work permit:
Name of the Site Safety Officer:
Name of site supervisor:
Work Permit sought for: (Please tick in the box)
Piling Excavation & backfilling Formwork at G.L.
Reinforcement work at Hot Jobs Mechanical
yard handling/shifting/transportation
Formwork/rebar work Concreting Structural Erection
at height
Electrical Installation Maintenance/repair Other works at height
Finishing works Grinding/chiseling Demolition
Miscellaneous works
(please specify)
Working on fragile roof

Work Description:

Location:

I confirm that I have been given charge of the above mentioned work and I will take all necessary
precautions to avoid danger to the workers engaged at the above site as well as property. I will
abide by the recommendations of the Safety Officer and implement them and I will assign jobs to
only trained personnel.

(Name and Signature of Site Engineer)

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (To be filled in by Safety Officer before issuing work permit) ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Following safety precautions are taken care of:

Sl. No. Safety Precautions Yes No NA
1. All concerned personnel are instructed about the nature of work
2. Access ladder/crawling ladder to work/roof provided & properly
secured
3. Safety clearance/check list for scaffold erection obtained/submitted
4. All workers have valid height passes
5. Safety net provided under the work place
6. Life line/Grab rope is provided at height
7. Work area is properly cordoned/barricaded
8. Work area is properly illuminated
9. Proper access to site is ensured
10. Openings are properly covered with safety net/steel jalli & barricaded
11. Electrical equipments are de‐energized (fuses removed)
12. Electrical equipments are checked for earthing
13. Portable electrical equipments are tested by site maintenance section
14. All rotating parts of machine are well guarded
15. Whether any inflammable is present in vicinity of the area of hot job
16. Fire extinguisher is available at the work site
17. Whether fire watch is required
18. Half‐an‐hour fire watch is compiled after hot jobs
19. Whether cylinders are kept vertically, properly tied and are under
shed
20. Work area is well ventilated
21. “NO SMOKING” board is displayed
22. Personal Protective Equipment (strike out whichever is not applicable)
Helmet/Shoe/Hand Gloves/Goggles/Ear Muff/Ear Plugs/Safety
Belt/Face Shield/Nose Mask/
23. Free escape route is available
24. Workers are in good health on the day of work

I have checked the safety precautions taken at site and allowed the work to be carried out.
Special precautions (if any)

(Name and Signature of Safety Officer)

Cc: 1. Safety Officer
2. Site Engineer
3. Site Supervisor
4. Departmental Representative
 Annexure ‐ 4
Part ‐ A
Application for Height Pass

Project

Group/Section: Contractor:

1. Applicant’s Name :

2. Departmental Address:

3. Residential Address :

4. Age :

5. Sex :

6. Height :

7. Gate Pass No. :

8. Name of contractor/Agency with

Whom engaged at present :

9. Height pass requirement for work at Mtr. Height.

10. Description of present job :

11. Previous experience of working at height:

Sr.No. Name of the Duration of Work Experience

Employer Employment
1.

2.
12. Is the applicant suffering from any of the following ailments (If yes details to be given):

Blood Pressure
Seizure disorder (Fits / Epilepsy Convulsion)
Flat Foot
d) Frequent attacks of headache or reeling sensation
e) Mental depression
f) Limping gait
Acrophobia (Fear of height)

Declaration:

I hereby declare that the above information furnished by me is true and correct. I shall always
wear the safety belt and tie the life‐line whenever working at unguarded heights of 3 mtrs and
above. I shall not misuse the height pass issued to me or transfer it to any other person. I shall
never come to duty or work at height/depth under the influence of alcohol/drugs.

Date: Name:

Sign:

(Applicants Name & Signature or Left Thumb Impression (LTI) in case he cannot sign. In case
of LTI; an authorized person shall explain each point/item to the individual and certify on his
behalf below the LTI).

I certify that I am satisfied with the above certification of the individual for the application of
Height Pass and request for issue of height pass to him.

Name:

Sign:

(Agency Concerned)
 Part – B
MEDICAL FITNESS CERTIFICATE

Certified that I, Dr. Have examined Shri.

Aged On (date) Of M/s.

Who has signed below in my presence. General &

Physical examinations of Shri. Do not reveal any abnormality. He

does not suffer from any acute/chronic skin disease or any contagious or infectious disease. His
eyesight is normal with/without glasses. In my opinion, Shri
is physically and mentally fit for working at height.
Details of examinations:

1. Age:

2. General & Systemic Examination:

2.1 Pulse 2.10 Depth of Vision Normal: Abnormal:

2.2 B.P. 2.11 Nystagmus : Present: Absent:
2.3 Weight 2.12 Rhomberg Sign: Positive: Negative:
2.4 Height 2.13 Hearing: Normal: Abnormal:
Muscular Co‐
2.5 Pallor Yes: No: 2.14 Normal: Abnormal:
ordination
Cardio Vascular
2.6 Flat foot Present: Absent: 2.15 Normal: Abnormal:
System
Respiratory
2.7 Gait Normal: Abnormal: 2.16 Normal: Abnormal:
System
2.8 Vision Normal: Abnormal: Central
Color 2.17 Nervous Normal: Abnormal:
2.9 Normal: Abnormal: System
Vision
3. Previous History of:
3.1 Seizure disorders (Epilepsy) Yes No
3.2 Frequent headache or reeling sensation Yes No
3.3 Mental depression Yes No
3.4 Acrophobia Yes No
4. Investigation:

4.1 Urine
Albumin:
Sugar:
4.2 Blood
CBC:
Random blood sugar (if age is >35 years.)

5. X‐ray:
Required / not required:
If required – details of report:

(Signature of workman) (Signature & Rubber stamp)

Of Medical Practitioner with Reg. No.
 Part – C
Height Pass Certificate

(Considering the above medical certificate; the applicant has appeared on the following practical tests
conducted by BARC and the results are given below (strike off whichever in‐applicable)
Affix
photograph
a) Walking freely over a horizontal structure bar : Pass / Fail (3.5cm x
at 1 ft. height 2.5cm)
For
b) Wearing a safety belt and tying the rope knot : Pass / Fail contractor
workers only
c) Walking over a horizontal structure at 10 ft. : Pass / Fail
height wearing a belt.

The above applicant’s performance in the above tests has been satisfactory/ unsatisfactory.

I certify issue of this height pass to Shri Of M/s.

with Registration No. In the height pass

register. This is valid for one year from the date of issue i.e. up to .

Date : Signature :
Name :
(Safety Supervisor)

Signature :
Name :
(Safety Officer)
 Annexure ‐ 5

FORMAT FOR SAFETY CHECK LIST FOR HEAVY DUTY TOWER / SCAFFOLDING ERECTION
(To be filled in by contractor in TRIPLICATE)
Name of the work:
Name of the principal contractor:
Ref. No.: Date:
Location / Block / Grid:
(Please tick in the box)
Sl. No. Checklist points Yes No Remarks
A. Check the base of the scaffolding:
1. Is the ground below base plate levelled and firm?
2. Are the base plates/sole plates provided or are
Proper supports placed under the structure?
3. Is the base away from excavation, drain cover,
Manhole, etc.?
4. Is there any vehicle movement near structure?
5. Is the frame supported on any make‐shift
Arrangements like barrels, boxes, concrete blocks,
bricks, empty drums, etc.?

B. Check the structure:

1. Are all members in good condition (free from bends,
Cuts, rust, etc.)?
2. Whether all the vertical members in plumb and
Correctly spaced?
3. Whether the joints of frames/vertical members are
properly connected with couplers & spring‐lock
Pins/cuploks?
4. Are all vertical & horizontal bracings provided and
Are they properly tied with pins/swivel couplers?
5. Whether the scaffold structure is securely tied /
restrained with permanent structure? (max. vertical
height between ties is 4 times of the least base
width)
6. Is there any electrical cable / wire within 5m above
The top most part of the structure?

C. Check the working platform:

1. Is the working platform at least two boards wide?
2. Is there any gap in the working platform?
3. Whether the condition of the scaffold boards is
good?
4. Whether the ends of the scaffold boards / jallis are
securely tied at the ends?
5. Is the overlap of the boards at least 300 mm?
6. Whether the last scaffold board is extended at least
600 mm beyond the end of the wall?
7. Are the guard rail and knee rail provided at 1.00 m
and 0.50 m height from the working platform?
8. Whether toe board of good condition and of min.
150 mm height is provided?
9. Whether the working platform is over loaded?
10. Whether safety net is provided below the working
the platform?

D. Check the access:

1. Whether stair/monkey ladder/walkway are
provided as access?
2. Whether the access is properly supported / tied /
made?
3. Whether the steps / landing of the access have any
slip resistance arrangement?
4. Whether the access steps / landings are free from
any obstacle and undesirable & slippery materials?
5. Whether the entry / exit of the access is free from
any obstruction

E. Housekeeping and maintenance:

1. Are all debris / undesirable material removed from
the working platform and access?
2. Are all the scaffold members maintained from time
to time?
3. Are all the damaged / weakened parts of the
scaffold immediately removed or replaced?

F. Safety tag:
1. Whether safety tag “unsafe scaffolding” / “safe
scaffolding” is displayed in the language understood
by majority of the workers?

(Name & Signature of Site Engineer) (Name & Signature of Safety Officer)
 Annexure ‐ 6

FORMAT OF CERTIFICATE OF TEST AND THOROUGH EXAMINATION OF CRANE BY THIRD PARTY

(To be filled in TRIPLICATE)

Sl. Description Details

No.
1. Name and address of contractor
2. Name and address of manufacturer of the crane
3. Type of Crane and nature of power
4. a) Date of manufacture of the crane
b) Date of first use of the crane
c) Date of last examination of the crane
5. Identification No.
a) Manufacturer’s serial number
b) Owner’s distinguishing mark / number
6. Safe Working Load(s) Length of Radius Test Load Safe Working
jib (M) (M) (MT) Load (MT)
(1) (2) (3) (4)
In case of a crane with variable operating radius,
the safe working load at various radii of the jib,
trolley or crab must be given. Test loads at
various radii shall be given in column (3) and in
the case which has been calculated without the
application of a test load, ‘NIL’ shall be entered in
that column.
7. In case of a crane with a derricking jib or jibs, the
maximum radius at which the jib or jibs may be
worked (in m)
8. Defects noted and alterations or repairs required
before crane is put into service (if none, enter
‘NIL’)
I hereby certify that the crane described in this certificate was tested and thoroughly examined by me on
(date: / / ) and that the above particulars are correct.
Date of certification:

(Signature & stamp)

(Qualification)
(Name & address of the Person, Company or Association by whom the person conducting test and
examination is employed)
 Annexure – 7
FORMAT OF CERTIFICATE OF TEST AND THOROUGH EXAMINATION OF HOIST BY THIRD PARTY
(To be filled in TRIPLICATE)

Sl. No. Description

1. Name and address of contractor
2. a) Type of hoist or lift and identification
number and description
b) Date of manufacture
c) Date of last overhauling / substantial
alteration
3. Design and manufacture:
Are all parts of the hoist or lift of good
mechanical construction, sound material
and adequate strength?
4. Maintenance: Are all following parts of the
hoist or lift properly maintained and in
good working order? If not, state what
defects have been found
a) Enclosure of hoist way or lift way
b) Leading gates and cage gate(s)
c) Interlock on the leading gates and cage
gate(s)
d) Other gate fastenings
e) Bucket or cage or platform and fittings,
gates, buffers, hoist way
f) Over running devices
g) Suspension ropes or chains and their
attachments
h) Safety gear i.e., arrangements for
preventing fall of bucket or platform or
Cage.
i) Brakes
j) Worm or spur gearings
k) Other electrical equipment
l) Other parts
5. Which parts (if any) were inaccessible?
6. Repairs, renewals or alterations required to
enable the hoist or lift to be used or to
continue to be used with safety:
a) Immediately
 b) Within a specified time, the time is to be
stated
If no such repairs, renewals or alterations
are required, enter ‘NIL’
7. Specify defects (other than those specified
at 5 above) which require attention
8. If no defects requiring attentions are found
and no repairs, renewals or alterations are
required then state that the hoist or lift is
In safe working condition.
9. Maximum safe working load subject to
repairs, renewals or alterations (if any)
Specified at 5.
10. If the hoist is to be used for the carriage of
passengers specify the maximum number
of passengers that may be carried safely.
11. Other observations

I hereby certify that on (date: / / ) I thoroughly examined this hoist or lift and the
that the foregoing is a correct report of the result.

Date of certification:
(Signature & stamp)

(Qualification) [Name
& address of the Person, Company or Association by whom the person conducting the test and
examination is employed]
 Annexure 7A

REGISTER OF PERIODICAL TEST – EXAMINATION OF LIFTING APPLIANCE AND GEARS, ETC.

(As per Form XXVI, BOCW Central Rules, 1998)

PART‐I

INITIAL AND PERIODICAL LOAD TEST OF LIFTING APPLIANCES AND THEIR ANNUAL THOROUGH
EXAMINATION

“Thorough examination” means a visual examination, supplemented, if necessary, by other

means such as a hammer test, carried out as carefully as the conditions permit, in order to arrive
at a reliable conclusion as to the safety of the parts examined, and if necessary, for such
examination parts of the lifting appliances and gear shall be dismantled.

(A)
Initial and periodical load tests of lifting appliance
Situation and No of I certify that on the date on which I have Remarks
description of lifting certificate of appended by signature the lifting (to be,
appliances tested test and appliance shown in column (a) was tested signed and
with distinguishing examination of and no defects affecting its safe working dated)
number of marks if competent condition were found other than those
any person shown in
column (5)
Date and Date and
signature signatur
with e
seal with seal
(1) (2) (3) (4) (5)
1.
2.

(B) Annual thorough examination:

I certify that on the date to which I have appended my signature, the lifting appliance
shown in column (1) was thoroughly examined and no defects affecting its safe working
conditions were found other than those shown in column (12)

Date and Date and Date and Date and Date and Date and Remarks to
signatur signatur signature signatur signatur signatur be signed
e e with seal e with e with e with and
with seal with seal seal seal seal dated
(6) (7) (8) (9) (10) (11) (12)
1.
2.
 PART II

Initial and periodical load test of loose gars and annual thorough examination:

List of loose gear:

The following classes of loose gears namely‐
1. Chains made of malleable cast iron;
2. Plate link chains;
3. Chains, rings, hooks, shackles and swivels made of steel;
4. Pitched chains;
5. Chains, rings, hooks, shackles and swivels permanently attached to pitched chains,
pulley blocks, containers, spreaders, trays, slings, baskets etc. and any other similar
gear
6. Hooks and swivels having screw threaded parts or ball bearings or other case
hardened parts; and
7. Bordeaux connections

Initial Test and Periodical Load Test of Loose Gears

Distinguishing Description of No of I certify that on the date on which I have
no. or marks loose gear certificates of append my signature the loose gears
tested and test and shown in column (1) and (2) were tested
examined examination of and no defects affecting the safe working
competent condition were found other than those
person shown in column (6)
Date and Date and
signature signature
with seal with
seal
(1) (2) (3) (4) (5)
1.
2.
3.
4.

Annual Thorough Examination of Loose Gears

Remarks I certify that on the date to which I have appended my signature the loose gears
(to be shown in column (1) and (2) were thoroughly examined by me and no defects
signed and affecting their safe working condition were found other than those shown in
dated) column (10)
Date and Date and Date and Remarks (to be signed
signature signature signature with and dated)
with with seal
seal seal
(6) (7) (8) (9) (10)
1.
2.
 PART III
Annealing of chains, Rings, Hooks, Shackles and Swivels (other than those exempted)
(SEE PART II)

12.5 mm and smaller chains, rings, hooks,
shackles and swivels in general use. Other
chains, rings, hooks, shackles and swivels in
general
If used with lifting appliance of driven by
power, must be annealed once at least in every
six months.
If used solely with lifting appliance worked by
hand, must be annealed once at least in every
twelve months.
If used with lifting appliance driven by power,
must be annealed once at least in twelve
months.
If used solely with lifting appliance worked by
hand, must be annealed once at least in every
two years.

NOTE: It is recommended though not required by rues that annealing should be carried out in a suitable
constructed furnace heated to temperature between 1100 degree and 1300 degree Fahrenheit or 600
degree and 700 degree Centigrade, for a period between 30 and 60 minutes

Distinguishin Description No. of the I certify that on the date to which I have Remarks
g no. and of gear certificate appended my signature, the gear (to be
mark annealed of test and described in cols. 1 & 2 was effectually signed and
examinatio annealed under my supervision; that dated
n after being so annealed every article was
carefully inspected and that no defects
affecting its safe working condition were
found other than those shown in col. 7
Date and Date and Date and
signatur signatur signatur
e e e
with seal with seal with seal
(1) (2) (3) (4) (5) (6) (7)
 Annexure ‐ 8
CONTENT OF A FIRST AID BOX
(as per Schedule – III, BOCW Central Rules, 1998)

1. A sufficient number of eye wash bottles filled with distilled water or suitable liquid clearly
indicated by a distinctive sign which shall be visible at all times.
2. 4 per cent xylocaine eye drops, and boric acid eye drops and soda‐bi‐carbonate eye drops.
3. Twenty four small sterilized dressings.
4. Twelve medium size sterilised dressings.
5. Twelve large size sterilised dressings.
6. Twelve large size sterilised burn dressings.
7. Twelve (fifteen cm) packets of sterilised cotton wools.
8. Two hundred ml bottle of certimide solution (1 per cent) or suitable antiseptic solution.
9. One (two hundred ml) bottle of mercurochrome (2 per cent) solution in water.
10. One (one hundred twenty ml) bottle of salvolatile having the doses and made of
administration indicated in the bottle.
11. One pair of scissors.
12. One roll of adhesive plaster (six cm x one meter)
13. Two rolls of adhesive plaster (two cms x one meter)
14. Twelve pieces of sterilised eye pads in separate sealed packets.
15. A bottle containing hundred tablets (each of three hundred twenty five mg) of aspirin or
any other analgesic.
16. Twelve roller bandages five cms wide.
17. Twelve roller bandages ten cms wide.
18. One tourniquet
19. A supply of suitable splints
20. Three packets of safety pins.
21. Kidney tray.
22. A snake bite lancet.
23. One (thirty ml) bottle containing potassium permanganate crystals.
24. One copy of first aid leaflet issued by Director General
25. Six triangular bandages.
26. Two pairs of suitable, sterilized, latex hand gloves.

Tablets for: fever, headache, body ache, stomach ache, loose motion, acidity, cold, upper respiratory trac
infection, urinary tarc infection, low backache, abdomen pain, minor injuries, Tab. Sorbitrate, Cap.
Nefedine, etc.
 Annexure 9
Articles for Ambulance Room/First Aid Post
(as per Schedule – IV, BOCW Central Rules, 1998)

1. A glazed sink with hot and cold water always available.

2. A table with a smooth top at least 180cm x 105 cm.
3. Means for sterilizing instrument
4. A couch and three chairs.
5. Two Stretchers and one examination bed with bed sheet, a pillow and cover
6. Two buckets or containers with close fitting lids and two rubber hot water bags.
7. A kettle and spirit stove or other suitable means of boiling water.
8. Twelve plain wooden splints 900cm x 100cm x 6cm.
9. Twelve plain wooden splints 350cm x 75cm x 12cm.
10. Six plain wooden splints 250cm x 50cm x 12cm.
11. Six wooden blankets.
12. Three pairs artery forceps.
13. One battle of spiritus annemiae arenatuins (120ml).
14. Smelling salt (60gm)
15. Two medium size sponges.
16. Six hand towels.
17. Four kidney trays.
18. Four cakes of toilet soap, preferably antiseptic soap.
19. Two glass tumblers, two wine glasses, two tea spoons and two clinical thermometers.
20. Two graduated (120ml) measuring glasses.
21. Two minimum measuring glasses.
22. One wash bottle (1000cc) for washing eyes.
23. One bottle (one liter) carbolic lotion 1 in 20.
24. One screen and one electric hand torch.
25. Four first‐aid boxes or cupboards.
26. An Adequate supply of tetanus toxide.
27. Injections‐ morphia, pethidine, atrophine, adrenaline, coramine, novocaine (6 each).
28. Cramine liquid (60ml).
29. Tablets‐ antithistaminic antispasmodic (25 each).
30. Syringes with needles‐2cc, 5cc, 10cc, and 500cc and needle destoryer
31. Three surgical scissors
32. Two needle holders, big and small.
33. Suturing needles and materials.
34. Three dissecting forceps, three dressing forceps and three scalpels.
35. One stethoscope and one Blood Pressure apparatus.
36. Rubber bandage‐pressure bandage.
37. Oxygen cylinder (min. 330 liter’s capacity) with necessary attachments and one Ambu bag.
38. Weighing machine, measuring, near vision chart, distance vision chart, wash basin, high pressure
drum for sterile items – one each.
39. Atropin eye ointment
40. IV fluids and sets – ten numbers
41. Suitable, foot operated, covered, refuse containers
42. Adequate number of sterilized, paired, latex hand gloves
Injections and other materials: Inj. Dexamethasone, Inj. Hydrocortisone, Inj. Avil, Inj. Dopamine, Inj.
Adrenelin, Inj. Deriphyllin, emergency control drug, demulcent drink, etc.
 Annexure ‐ 10

FORMAT OF OBSERVATION REGISTER OR COMPLAINT RECORDS

(To be filled in by Safety officer or Site Engineers)

Sl. Date Area/ Observation/ Remedial Name of Action Signature

No. location hazard measures person taken on of Safety
recommended responsible Officer
 Annexure ‐ 11
FORM NO. SGCW ‐ 1
FORM FOR COMPLETION CERTIFICATE
(Prescribed under Cl.1.2 of Annexure of AERB Safety Guide for Works Contract))

I/We certify that the installation detailed below has been installed by me/us and tested and that
to the best of my/our knowledge and belief, it complies with Indian Electricity Rules, 1956 as well
as IS: 732‐1963 code of practice for Electrical Wiring Installations. [System voltage not exceeding
650 Volts (Revised)].
Electric installation at..............................................................................................................
Voltage and system of supply a)
Particulars of work Number Total load Type of system of wiring
i) Light Points
ii) Fan points
iii) Plug points (3 pin)
iv) Motors

b) If the work involves installation of overhead lines and/or underground cable

c) Earthing:
Description of earthing electrode, size of earth wire and number of electrodes provided:

d) Test results:
1. Insulation resistance for the whole installation:
i. Between conductors:

ii. Between each conductor and earth:

2. Resistance of earthing electrode or earthing system

3. Maximum earthing resistance of installation

( ) ( )
Signature of Supervisor Signature of Contractor
Name and address of Supervisor Name and address of Contractor.
 Annexure ‐ 12

FORM NO. SGCW‐2

‘A' APPLICATION FOR SERVICE CONNECTION BY CONTRACTOR
(Prescribed under Cl.1.3 of Annexure of AERB Safety Guide for Works Contract)
(To be filled in
triplicate)
1. Name & Address of Contractor:
2. Reference to Tender & Work Order:
3. Completion period:
4. Connected load details:
(Please attach details in a separate sheet)
5. Max. demand anticipated :
6. Nature of service connection required:
(Whether single or three phase)
7. Place where service required:
a) Works:
b) Colony:
8. If supply of electricity is free or chargeable:
(Please enclose extract of conditions from the tender)
9. Details of meter provided:
a) If meter required from the Department, whether Security Deposit is paid:
b) Details of SD (Security Deposit):
c) Whether meter is tested or not, if tested, attach test report, if not, details of testing fee
deposited:
10. Name of Supervisor/Electrician in charge of installation and maintenance:
11. Electrical license No. of person mentioned against col. 10:
12. Electrical safety appliances available for use:
13. Fire extinguishers available for use:
14. First Aid facility/box available for use, if any:

(Signature of the Contractor)

Name:
Date:
 ‘B’ CERTIFICATE BY THE CONTRACTOR

Certified that my/our installations have been carried out in accordance with I.E. Rules and
that I/We have employed competent persons to handle the installations.
I/we am/are agreeable to the bills, in respect of this service connections being raised on
the basis the connected load furnished above, in case the actual consumption falls below the one
stipulated by the tender conditions.

(Signature of the contractor)

Name:
Address:
Date:

‘C’ CERTIFICATE BY THE CONTRACT CONTROL ENGINEER

Verified the particulars and forwarded to the Engineer In charge.

(Signature of Contract control Engineer)

Name:
Section: Civil/Electrical/Mechanical.

‘D' CERTIFICATE BY THE ENGINEER IN CHARGE

Certified that the particulars furnished by the Contractor are true to the best of my
knowledge and belief and that I have satisfied myself as to the safe conditions of electrical
installations for which the service connection is applied for.

Signature:
Name:

Date: Designation with section:

‘E' CERTIFICATE BY THE SAFETY ENGINEER

Certified that I have inspected the electrical installations referred herein and after
satisfying myself about the safe conditions of the installation, I hereby recommend that the
service connection be given to the Contractor.

Signature of Safety Engineer.

Date: Name:
‘F' AUTHORISATION BY THE ELECTRICAL ENGINEER
Service connection may be/may not be given for the reasons noted hereunder.

Signature of Electrical Engineer.

Name:
Date: Designation:

'G' 'REPORT OF COMPLIANCE'

Service connection is given by me on

a) Meter Nos. 1.
2.

b) Initial readings: 1.
2.

c) Locations: 1.
2.

d) Meter Sealings: 1.
2.

Signature of Electrical Engineer

(Metering and Billing)

Name:
Date: Designations:

Note:
1st copy to Contract Control Engineer
After all the formalities are completed and
2nd copy to Safety Engineer
Report of Compliance Electrical Engineer after
power supply is given.
And 3rd copy to Electrical Engineer
 Annexure 13
FORMAT FOR INJURY REPORT FOR CONTRACT/CASUAL WORKER

1. Name of the injured person:

2. Age: Sex: Male / Female
3. Date and time of the accident:
4. Place where the accident occurred:
5. Name of Project and Contractor:

6. Name of contracting division/section:

7. Name of BARC supervisor:

8. Nature of job:

9. Was this his regular job?

10. How did the accident occur (please give details):

11. Nature of injuries:

12. Was the patient referred to hospital?

13. If yes, whether admitted:
14. What was wrong with the working method/instructions:

15. What was defective? Any unsafe condition existed?

16. Was the accident due to fault of any person other than injured?

17. If yes, who and how?

18. Did any similar accident occur earlier in the project?

19. What safe guards / instructions could have prevented the accident?

20. What steps will be taken to prevent recurrence of similar accident?

(Name & Signature of Contractor)

(Name & Signature of Engineer‐in‐charge)

21. Comments from Head of the contracting Division/Section:

(Head of Contracting Signature Division/Section)

 Annexure 14

FORMAT FOR INSPECTION OF FIRE EXTINGUISHERS

Sl. Fire Type of Fire Date of Date of Status Place of Fire Signature
No. Extinguisher Extinguisher monthly annual Extinguisher
No. inspection inspection
 Annexure 15

FORMAT FOR TESTING OF PORTABLE AND OTHER ELECTRICALLY OPERATED EQUIPMENT

Sl. Name of Capacity IR value 3 Ph IR Value Remarks

No. Equipment (HP) 1Ph
R M Y M B M

(Name & Signature of Contractor) (Name & Signature of Dept. Representative)

Annexure 16

A&CED: Architecture & Civil Engineering Division AEFR : Atomic Energy Factory
Rules
AERB : Atomic Energy Regulatory Board
ASTM: American Society for Testing and Materials BOCW: Building and Other
construction Workers BS : British Standards
DB : Distribution Board/ Box DCP: Dry Chemical Powder DG : Diesel
Generator
ESG : Engineering Services Group ELCB : Earth Leakage Circuit Breaker HRC :
High Rupturing Capacity
IHSS : Industrial Hygiene and Safety Section IS : Indian Standards
 Kmph : kilometer per hour KVA : kilo‐volt‐ampere
MCB : Miniature Circuit Breaker MS : Mild Steel
PCC : Plain Cement Concrete
PPE : Personal Protective Equipment Re‐bar: Reinforcement bar
RCC : Reinforced Cement Concrete RMC : Ready Mix Concrete
RPM : Revolution per Minute
RSSD : Radiation Safety Systems Division QA : Quality Assurance
QC : Quality Control SU : Safety Unit
SLSC : Site Level Safety Committee
SIDE : Switch off, Isolate, Discharge and Earth UV & IR: Ultra Violet & Infrared
Radiation
WC : Water Closet

Context of Organization:
Understanding the Organization and its Context:
External and internal issues that are relevant to and can affect the purpose of the ability to
achieve the intended outcome of information security management system varies from unit to
unit. Hence these requirements shall be addressed at the individual unit level.
Understanding the Needs and Expectations of Interested Parties:
Interested parties that are relevant to the information security management system may include
but not limited to the following:
 Customers - External & Internal
Corporate IT
Suppliers
Vendors, etc.

The requirements of these interested parties relevant to information security may be but not
limited to the following:

Project Requirements
Contract requirements
Legal and regulatory requirements
Corporate policies and requirements, etc.

Section V - Document Control

This Manual shall be made available as a read only document to all employees through the Intranet Website.
Employees are encouraged to read the manual, understand their individual responsibilities and play their due role in
ensuring Information security in the organization.

This manual is an internal document and hence shall not be made available to anyone other than the employees.

Revision

Changes happen on many fronts - technology, applications, our organizational relationships and the environment.
These changes may affect our information systems and the security set up. Corresponding changes shall be
addressed to the manual as and when required. These changes will however be made as distinct version changes
which can be tracked. After changes, the manual will be reviewed in IT Security forum and approval from all IT Heads
will be taken, the IS Manual shall be posted on the website with suitable notifications.

The Master copy of the document will however be maintained by MSC.

1.1Following Instructions
All security personnel and officers are to obey all instructions and commands given by their superior officers either in writing or verbally
without fail.

1.2Discipline
All security personnel must be disciplined and courteous to all occupants, visitors, public, superiors and subordinates at all time.
1.3Attire
All security personnel must be in full uniform to include headgear whilst on duty. Hair must be kept short and tidy at all time.
1.4Work Procedures
1.4.1 All security personnel must be alert at all times.
1.4.2 All security personnel are not allowed to site or chit-chat in any of the shops or offices in the building.
1.4.3 All security personnel are not allowed to lean against a wall or appear sleepy while at their respective posts of duty.
1.4.4 All security personnel are not allowed to leave their post whilst on duty or before a replacement guard arrives.
1.4.5 All security personnel are not allowed to sleep whilst on duty.
1.4.6 All security personnel are not allowed to neglect their duties.
1.4.7 All security personnel are to report all incidents that happened within their area of responsibilities to their superior officer.
1.4.8 All security personnel are not allowed to consume alcohol or be under the influence of alcohol or drugs whilst on duty.
1.4.9 All security personnel are not allowed to take into possession or safe keeping any properties, stocks, displays, unattended item
whether valuables or not without proper authorization or means or sales and transfers.
1.4.10 all security personnel are not allowed to stay or wander around their working post whilst on leave, off duty or after duty.
1.4.11 All security personnel are not allowed to carry any video instruments or cameras whilst on duty unless authorized by the
management.
1.4.12 All security personnel are not allowed to abuse , enter into a quarrel, fight or use abusive languages against the management
,superiors, occupants, colleagues or visitors at all times unless their own life is threatened.

1.5Security Vetting
All security personnel must be properly vetted to ensure that they are free from criminal records within three months of their months of
their enrolment. Those who fail in the vetting are to be dismissed from the company.
1.6Health
All security personnel must be physically and mentally fit to perform their duties.
1.7Equipment
All security personnel must be fully equipped with a note book, pen, whistle, baton, identification tag, walkie-talkie, torch light, rain coats
and umbrellas.
Log Books
All security personnel must ensure all diaries and record books are to be kept in good order and produced for verification by their
superiors and/or the management from time to time.

1.0RECORD BOOKS
2.1Incident Report Book
2.1.1To record all incidents in the building with comprehensive details of occurrence, action taken including any follow up action or in
progress their required recommendations.
2.1.2To be kept in a proper order for reference, induced as a supporting facts or evidence in the filing of the incidents with the local
authorities subject to the written consent of the management and the report should be treated as private and confidential.
The incident report should tally and act as precedence to any separate or detailed report to be submitted by the management to the
management or any local authorities with the written consent of the management.
2.1.3All incident reports are to contain the following basic information: -
2.1.3.1 Full name, designation and the identification number of the person submitting the report.
2.1.3.2 The date, time and location of the incident.
2.1.3.3 Details of the person full name(s), identification number(s), vehicle shop lot(s), office unit, value, items, damages, type of incident
involved and any other relevant information.
2.1.3.4 Personal particulars of the witness(es), address(es), identification number(s), contact numbers- mobile phone, office and
residential, if any.
2.1.3.5Action(s) taken, follow up action(s) or in progress action(s) required and recommendations.
2.1.3.6 Investigation details as to the cause of the incident, contributing factors, suspected persons or factors, how the incident occurred
and its impact on the security of the building.
 
2.2Visitors Log Book
2.2.1Visitors entering during the operational hours are to register with the security guard at the guard house and to be observed on the
full compliance of the house rules and any rules and regulations as assigned by the management.
2.2.2All visitors and occupants entering the building after the operation hours are required to register at the guard house. Details to be
included are date, time in, time out, full name, identification number, place of destination, reason and the person’s signature.
2.3 Contracts Log Book
2.3.1All Contractors doing renovation, repair and maintenance works are required to register and obtained contractor passes at the guard
house. Details to include in the record book are date, time out full name, identification number, vehicle registration number, place of
destination, reason and the workmen signatures.

Appendix - Policies and Guidelines

List of Policies/ Guidelines

Sl. No Policy / Guidelines

I Information Security Policy

II Access Control Policy

III Information Security Policy for Project Sites

VI Information security policy for supplier relationships

V ITSA Responsibility Guidelines

VI Risk Assessment guidelines

Information Security Policy

1.0 Purpose

The purpose of Information Security Management is to protect information assets from all threats, vulnerabilities,
whether internal or external, deliberate or accidental thereby ensuring incessant services to customers and other
interested parties. The implementation of this policy is important to maintain our integrity as a supplier of product /
service to both internal and external customers.

2.1 Definition of Information Security Management System

 “Information can exist in many forms. It can be printed or written on paper, stored electronically, transmitted by post
or using electronic means, shown on films, or spoken in conversation.

Whatever forms the information takes, or means by which it is shared or stored, it should always be appropriately
protected.”

Information security aims at protecting information from a wide range of threats in order to ensure business
continuity, minimize business damage and maximize return on investment and business opportunities. The 3 basic
components in Information Security Management are:

1. Confidentiality - Ensuring that information is accessible on to those authorized to have access.

2. Integrity - Safeguarding the accuracy and completeness of information and processing methods.
3. Availability - Ensuring that authorized users have access to information and associated assets when required.
A system designed to meet the three basic components of Information Security and to provide protection to assets
from vulnerabilities and threats is Information Security Management System.

3.0 Management intent

The management of endeavours to support the establishment of security systems, set a clear policy direction and
demonstrate support for, and commitment to, information security through the issue and maintenance of a Security
Policy across the organization and user groups.

4.1 Objectives

1. Protection of customer property and proprietary information

2. Protection of company’s information & information processing assets. (Measurable objectives e.g. virus attacks,
system crashing, server failure, backup not restorable, loss of data, etc.)
3. Adoption of a systematic approach to risk assessment and risk treatment.

4. Provide a comprehensive Business Continuity Plan encompassing the respective unit/ location
5. Identify the value of information assets and to understand their threats & vulnerabilities through appropriate risk
assessment.
6. Manage the risks to an acceptable level through design, implementation and maintenance of a formal
Information Security Management System.
7. Comply with regional & international legislation relating to our services:
8. Comply with Contract conditions.
9. Comply with the company corporate directives.

5.0 Scope of the ISMS

 The scope of this policy includes to all units mentioned in section IV.

6.0 Applicability

This policy is applicable to users of all information, explicit as well as implied, including all contractual
partners of the organization.
9.1
7.0 Delegation and Responsibility Allocation

The top management shall form an Information Security Management Forum to guide the entire
organization in implementing the policy. All Unit Heads/HODs will check for compliance with the policy
within their area of responsibility and within their skill sets. They will guide/participate in carrying out
risk assessment and risk treatment plans. All users will abide by this policy and all related policies and
procedures. They shall also report security incidents and weaknesses to designated personnel. A
database of security skill sets shall be created, maintained and made available at individual
unit/location.

9.2 Specific policies

1. Acceptable Use Policy
2. Access Control Policy
3. Secure Development Policy
4. Information security policy for supplier relationships

9.3 Regulatory

1. Compliance with regulatory requirements both Regional and International, specific with our
service segments including,
2. Information Technology Act, 2008(Amendments)
3. Indian Copyright Act 1957
4. Indian Patent Act 1970
5. Indian Contracts Act, 1872

10.0 Disciplinary Actions

Compliance with the policy and procedural requirements shall be effectively monitored to ensure
proper reporting mechanisms in case of lapses and penal provisions for nonconformance.

11.0 Review
 This policy shall be reviewed periodically once a year during IT Security Coordination meeting and
where cases of influencing changes occur; it shall be appropriately modified & documented to
meet our business requirements and our ability to serve our customer

Access Control Policy

1.0 Overview

(Henceforth referred as the “Organization”) intentions for publishing an Access Control Policy are
not to impose restrictions that are contrary to the established culture of openness, trust and
integrity
2.1 Purpose

The purpose of this policy is:

1. To outline the proper access level for information and information processing assets
2. To protect the information and information processing assets of the Organization and its
customers by having proper access control
3. To prevent exposure to risks including unauthorized access, loss of information and disruption
in network services

3.0 Scope

This policy applies to all employees and external parties of the Organization. It also applies to all
information and information processing assets that are owned or leased by the Organization or
customer / contractual partner provided.

4.1 Policy

To ensure that the information and information processing assets of the organization are accessed
only by the authorized personnel, the following shall be implemented.

1. The login IDs for getting logical access to the Organization’s network resources shall be created
for an employee / external party only based on approval from the concerned dept. heads /
authorized person.
2. Depending on the job responsibilities, the Project manager / Dept. Head shall request the ITSA
to allot rights, clearly identifying the resources and the type of rights. Based on the request
received, ITSA shall provide the necessary access.
3. As defined at individual unit level, the access rights shall be reviewed periodically by the ITSA
in coordination with the Project manager / Dept. Head.

4. On termination / separation of an employee, the ID shall be deleted / disabled with immediate

effect by ITSA, on receipt of intimation from personnel dept. / concerned dept. head.
5. In case it is necessary to access the information using such ID, the same shall be kept enabled
for specific number of days, upon request received from the Project manager / Dept. Head, by
changing the password. The change shall be intimated to the Project Manager / Dept. Head.
6. Only admin equivalent users shall have the access rights to system files. Users shall have no
rights to system files
 7. The configuration / modification of the network devices such as switches, routers, etc., shall be
carried out by ITSA / nominated personnel only. For such activity, the admin ID shall be used.
For monitoring purpose, separate ID with limited access shall be created to prevent any
unauthorized/ unwanted change in the configuration.
8. Records of all significant events concerning the use and management of user identities and
secret authentication information shall be archived.
9. The allocation of privileged access rights should be controlled through a formal authorization
process.

5.0 Enforcement

Any employee found to have violated this policy may be subject to disciplinary action, up to
and including termination of employment, based on the severity of violation and impact on
business operations. However management decision shall be considered as final.

CONVEYOR BELTS SAFETY PROCEUDRE

1. OBJECTIVE:
To evolve uniform safety procedure in Operation and Maintenance of Conveyors Belts for ensuring
the safety in O & M in Plants.
2. SCOPE:
This procedure applies to different types of conveyors used in l handling plants in all operating
sites.
 Sl.
Description
No.
SAFETY PRECAUTIONS DURING OPERATION WORK IN A
2.1
CONVEYOR BELT (TROUGH CONVEYOR)
SAFETY PRECAUTIONS DURING MAINTENANCE WORK IN A
2.2
CONVEYOR BELT (TROUGH CONVEYOR)
2.3 SAFE OPERATING PROCEDURE FOR PIPE CONVEYOR OPERATION
SAFE OPERATING PROCEDURE OF BELT JOINTING (PIPE
2.4
CONVEYOR)
SAFE OPERATING PROCEDURE FOR RETURN ROLLER
2.5
REPLACEMENT (PIPE CONVEYOR)
SAFE OPERATING PROCEDURE FOR IDLER REPLACEMENT (PIPE
2.6
CONVEYOR)
SAFE OPERATING PROCEDURE LUBRICATION OF CONVEYOR
2.7
ROTATING MACHINERY
2.8 STACKER CUM RECLAIMER

3. EXPECTED RESULTS:
3.1. Written down procedures for Operation and Maintenance of Conveyors Belts.
 3.2. Manage jobs being done in Conveyors Belts safely

3.3. Control of incidents in Jobs related to O & M of Conveyors Belts

3.4. Compliance to Regulatory requirements related to O & M of Conveyors Belts

3.5. Safety awareness among workmen in Handling Plant.

4. ACCOUNTABILITY & RESPONSIBILITY:

4.1. ACCOUNTABILITY: Concerned Division’s Heads / Assets
Custodian.

4.2. RESPONSIBILITY: Concerned Engineer in Operation and

Maintenance of Coal Handling Plant

5. GLOSSARY/ DEFINITIONS:

Danger zone: Any area inside or around equipment that presents a hazard to a worker’s health,
safety or physical integrity.

Intervention area: The area in and around equipment and the moving load, including access points
and integrated access ways.

Loading and unloading zones: Areas where loads are picked up or deposited, either manually or
automatically, after conveyance.

Maintenance tasks: Inspection, cleaning, unclogging, load un-jamming, greasing, adjustments, repairs
or other maintenance.

Production operations tasks: Start-up, shut-down and other operations such as loading and unloading,
assembly, fastening, labelling, coding, monitoring, etc.
Service way: An area around conveyor(s) reserved for access to equipment for operation and
maintenance.

Work area: A place at a work site where a worker is, or may be, present during work or during a
work break.

Job Safety Analysis (JSA): Job safety analysis is a procedure which helps integrate accepted
safety and health principles and practices into a particular task or job. In a JSA, for each basic
step of the job, it is to identify potential hazards and to recommend the safest way to do the
job.

Hazard: Source or situation with potential for harm, something that can cause body injury /
occupational illness, damage company property.

Hazard Identification & Risk Assessment (HIRA): Hazard Identification & Risk Assessment is to
identify and evaluate the hazards, Risk and put controls measures for safe execution of
activities.

Inspection: Checking the work permit controls in practice using a prepared checklist.

Lockout: Placement of a lockout device on an energy isolating device, in accordance with an

established procedure, ensuring that the energy isolating device and the equipment or material
being controlled cannot be operated or moved until the lockout device is removed.

Lockout device: A device that utilizes a positive means such as a lock, either key or combination
type, to hold an Electrical energy isolating device in a safe position and prevent the energizing
of a machine or equipment

Tag out: Placement of a tag out device (Danger Tag) on an energy isolating device, in
accordance with the applicable sections of this procedure, to indicate that the energy isolating
device and the equipment being controlled may not be operated until the tag out device is
removed. Tag out devices are placed in the same location as lockout devices.

Tag out device: A prominent Danger Tag, such as a tag and a means of attachment, which can
be securely fastened to an energy isolating device or source of systems containing hazardous
materials in accordance with an
Established procedure, to indicate that the energy isolating device and the equipment being
controlled may not be operated until the tag out device is removed. The tag is used only when
the equipment is incapable of being locked out and the equipment is disconnected from its
source of energy

SHE: Safety, Health & Environmental

Risk: The likelihood (probability) which can lead to potential negative consequences.

Risk Assessment: A systematic and structured process whereby hazards present in a workplace,
or arising from workplace activity, are identified, risks assessed / evaluated, and decisions
prioritized in order to reduce risks to acceptable levels.

ZSS Zero Speed Switch

LOTO Lock out Tag out

PPE Personal Protective Equipment

PTW Permit to Work

SAP System application product for data processing

6. STEPS OF PROCEDURE:

6.1. SAFETY PRECAUTIONS DURING OPERATION WORK IN A CONVEYOR

BELT
6.1.1 Belt sway (Belt Tracking)

1. Do not wear loose clothing or jewelry near the conveyor belt.

2. Do not put your hands on a moving conveyor belt.
3. Provide proper illumination at the working zone.
4. Insure the ‘OK’ condition of pull cord and emergency stop switch
Of the conveyor belt.
5. Keep one skilled person with ‘walky-talky’ near the pull cord.
6. Communicate with control room before aligning/tracking the running belt.

7. Move the trainer idler by pushing/pulling its frame from the ends only.
 8. Do not try to move any damaged/jammed trainer idler.
6.1.2 Spillage recovery/cleaning

1. Do not wear loose clothing or jewelry near the conveyor belt.

2. Do not put your hands on a moving conveyor belt.
3. Do not stand /walk on the belt.
4. The spillage material accumulated below the return side-belt or on the deck plate
should be cleaned by hand scrappers only.

5. The spillage material should be collected in bucket and it should not throw down
from conveyor gallery.
6. Throw the collected spillage material on belt, only from those positions, where the
safety guards are provided on belts as per
Safety standard SS/ENG-18.
7. Never heap up the spillage material at the tail end of the conveyor.

8. If the spillage material is in large amount (more than one ton), the conveyor

9. Should be taken in local operation mode. Start the belt in empty condition. Keep
one person at pull cord. Communicate with control room and start throwing the
collected spillage material by bucket on the running belt from the safety guard
positions only or
Station made for this purpose.

6.1.3 Start/Stop of belt

1. If a conveyor belt needs stopping, it should never be stopped in load condition,
except emergency.

2. If the high speed coupling in the drive is a fluid coupling, the number of start/stop of
the conveyor belt should not be more than 4Nos/Hr, at the same time there should be
a minimum gap of 15 to 20 minutes between two consecutive start & stop.
 6.2 SAFETY PRECAUTIONS DURING MAINTENANCE WORK IN A CONVEYOR
BELT

6.2.1 Conveyor drive

1. Stop the conveyor belt, when it is empty. Never stop the belt in
load.
2. Do the positive isolation of all the electrical power sources of
conveyor system.
3. Before changing/replacing of any component of the drive
(coupling, gearbox or motor), do the positive isolation of potential
energy source (take-up unit) of the belt by holding it with a pair of
suitable chain blocks. Select the chain blocks from table1. To hold
take up, lift it by 6-8 inches to take GTU load by chain blocks. It is
also desirable (although not a must) to place the ‘I’ beam/channel at
correct position under the gravity take up. Internal inspection of
gearbox components should be done through the provided
inspection cover only and its top cover should not be opened at site.

4. Whenever the gearbox or/and motor is required to change, the

factor of safety for the gearbox should not be less than 2.0
(Attention should be given at design/selection phase).
5. The oil level in fluid coupling should be maintained as per
mentioned quantity in its manual. The slip in fluid coupling should
be less than 3%.
6. In the pin-bush and gear couplings, the minimum gap between
the flanges should be maintained as per the recommended value
according to their size.
All the moving/rotating components of the drive should be covered by standard
safety guards

6.2.2 Counter Weight

 1. Stop the conveyor belt, when it is empty. Never stop the belt in load.
2. Do the positive isolation of all the electrical power sources of conveyor
system.
3. Spillage material accumulated on counter weight should be removed on
regular interval.
4. A counterweight and its pulleys suspended above the floor or ground, in
an area where an employee could walk, shall have an enclosure around the
area of impact or a catch pan under the counterweight of such strength and
design to hold the counterweight and pulley from dropping to the ground,
floor or platform.
5. The concrete slab type counter weight should be replaced by box type
closed counter weight.
6. The rope of the counter weight should be checked on regular
interval for its strands condition and bulldog grip looseness.
When, two wire ropes hang the counter weight, the wire ropes should be of
opposite hands. This will avoid twisting of counter weight about its vertical axis.

6.2.3 Chute (Receiving or discharge chutes)

1. Stop the conveyor belt, when it is empty. Never stop the belt in load.

2. Do the positive isolation of all the electrical power sources of conveyor

system as per the safety standard.
3. Before starting any job in receiving chute, power of the preceding belt or
feeding device must be isolated. Similarly, before starting any job in the
discharge chute, power of the succeeding belt must be isolated. In addition the
chute must be checked for loosely held material inside and cleaned before
entering.
4. The side skirt rubber should not be kept in contact with the belt. This may
create longitudinal groove on belt top cover and increase friction also.
5. The inside space between side skirt boards (left and right sides) should
be two third of belt width.
6. Never use metal plate or piece of belt as a side skirts it may damage the
belt.
7. An inspection cover/window should be given in chute at the non-impact-
wall. The inspection window can be used for dislodging the jammed material
on impact walls or inspection of inside condition of chute.
8. To protect the mother plate of a chute, the hard faced liner or wear resistant
liner plate should be fixed at the impact zone of chute walls.
 9. Before executing the welding or gas cutting job in chute, the belt below the
chute must be covered by a fire resistant cloth. 10. There must be proper
clearance between the pulley (discharge pulley or tail pulley) end face and
the inside wall of the chute.
If the dust content in the material handled is high, a dry fog or vacuum cleaning
system should be installed at the receiving
chute
6.2.4 Belt joint (Vulcanized or mechanical)

1. Stop the conveyor belt, when it is empty. Never stop the belt in load.
2. Do the positive isolation of all the electrical power sources of conveyor
system.
3. Fix the jam angle with deck plate/stringer at a sufficient free length (3 m to
5 m from the joint), towards head end of the conveyor belt.
4. To pull the loose belt, it should be clamped with a pair of angles (also
called as pulling angles) at a distance of 3 to 5 m
from the joint & towards tail end.
5. Pull the belt from the pulling angles with the help of suitable chain blocks &
slings.
6. Clamp the belt with a pair of jam angles and hold it with deck
plate/stringer. This should be at a suitable distance from the
pulling angles & towards tail end of the conveyor belt.
7. Before applying the adhesive the joint surface must be cleaned
thoroughly and the surface should made free from moisture.
8. In case of mechanical joints of belt, proper selection of fastener
and bolt tightening should be done as per the conveyor belt
standard MEG/TRANS/117/2007.
9. If there is pocket formation at joint or the edge of the joint is
found uprooted, it should be repaired immediately.
10. Precautions: In case of short length belt where tilting of belt is not possible,
exact length of belt to be spliced to avoid the
Dressing.

6.2.5 Pulley
 1. Pulley should be checked for its lagging condition (if lagging is
present), axial shift and its bearing condition on regular intervals.
2. Weld-joint condition of the disc with hub and shell of the pulley
should be checked at every six month.
3. Before starting the repairing or checking inspection work,
where pulley is required to touch, the steps explained in section
6.3.1 must be followed.
4. Entrapment of material between tail pulley and return- side belt
should be avoided by fixing an inclined plow/scrapper on the belt at
return-side.
5. If the bearing temperature of the pulley is found above 70 oC, the
grease quality, quantity and radial clearance of bearing should be
checked.
Always close the greasing points after completion of greasing.
6. The tail pulley of a conveyor belt should be guarded as per the
safety standard.
7. Ceramic lagging on bend pulley should be avoided
As it increases the friction and overall tension in the belt. If lagging is
required, preferences to rubber

Lagging should be given.

6.2.6 Idlers

1. The jammed or damaged idlers should be replaced

immediately, as they have high potential of damaging the belt
(specially the belt joint).
2. The space between two idlers should be maintained as per
standards, based on belt width and bulk density of material. For
example, for a belt of width 1200 mm and carrying material of
bulk density 1.2 t/m3 the distance between two toughing idlers
should be 1.0 m and that for return flat idlers should be 3.0 m.
3.Chute distance between two idlers to be 0.5 m to avoid belt
sag which should not be more than 2%.
The minimum distance between two trouping-trainer idler should
be 15 m and that for return trainer should be 30 m.
4. For better control on belt sway, the ‘tru-trac’ idlers can be used,
such as, In return side, fix the idler (i) at 4.0 m away from the tail
pulley. (ii) At about 2.0 m towards head end from the bend pulley of
GTU and
(iii) In return side, at 4.0 m away from the head pulley
6.2.7 Deck plate

1. Deck plate must be given below the toughing belt. It protects the
entrapment of spillage material between the rotating pulleys and
the belt.
 2. The locations where the conveyor gallery is passing over the road
or working area, the deck plate below the return belt must be
provided.
3. For repairing or fixing of a deck plate, the safety standard on
welding and gas cutting should be used.

6.2.8 Belt safety switches (ZSS, belt sway switch, pull cord)

1. The ZSS switch should be cleaned thoroughly on a regular

interval.
2. The length of lever of ‘belt sway switch’ should be in
The range of belt during belt sway.
3. The ‘pull cord switch’ with LED indicator should be used.
(Material No. 0380A0145 and 0713A0010) 4. Before repairing or
changing of belt safety switches, stop the conveyor belt, when it is
empty. Never stop the belt in load. Do the positive isolation of all
the
Electrical power sources of conveyor system as per the safety tagging
system.

6.2.9 Belt Changing job

1. Ref-Sketch 1
2. New belt roll should be put on a fabricated & heavy stand and roll shaft
to be locked from top on supporting points. The stand should be sufficiently
heavy or to be anchored with nearby structure. This is required to avoid
tilting of stand while the belt is being changed.
3. Belt changing area should be barricaded by safety ribbon and a safety
observer should be deployed throughout the job.
4. Stop the conveyor belt, when it is empty. Never stop the belt in load.
5. Do the positive isolation of all the electrical power sources of conveyor
system as per the safety tagging system.
6. Job must start after getting clearance in permit to work. Belt conveyor
should be put under local mode for belt changing activity. Power cut off
number may be given after
Complete belt changing).
7. Position the belt position (where the job has to do) at a suitable place
and stop the conveyor belt.
8. Do the positive isolation of all the electrical power sources of conveyor system
(including preceding and succeeding conveyors) as per the safety tagging system.

9. Before starting any activity in conveyor belt, do the positive isolation of

potential energy source (take-up unit) of the belt by holding it with suitable
chain blocks. Lift the Take-up by 6- 8 inches (Refer Fig 1).
10. Take-up must be lifted and held with two numbers of suitable and tested
chain blocks. Selection of chain block to be done as per the table 1.
11. It is also desirable (although not a must) to place the ‘I’ beam/channel at
correct position under the gravity take up, to avoid the free fall of take up. (Refer
Fig2).
12. Before cutting of old belt, it should be clamped properly with conveyor
deck plate by 2 nos. of jam angles (refer Table
2) On both side of the cutting position. (Refer Fig 4).
13. To avoid slip or damage of conveyor belt, a rubber piece should
be inserted in between the jam angle & conveyor belt.
14. The other end of old belt, which is supposed to be pulled out,
should be clamped with holding T shape plates.
15. Release the jam angles and pull the old belt manually or by
some external pulling device (Like winch or pay loader). The new
belt to be pulled from reel by inching drive with local switch. (Refer
Sketch-1).
The speed of pulling device should be very slow max. 15 meter/min.
If belt is longer (more than 250M and at height), three persons should
coordinate through Walky-Talky/Mobile Phone. One with local switch
operator, second with the pulling device and the third along with joint
movement.
If belt gallery is at more than 15 m height from ground, when about 5 to 8
m of new belt remains in the wooden reel, pulling of belt to be stopped.
Belt to be held in gallery at any point to avoid any
 Movement in the belt.
Open/un-wrap the new belt from reel and hold the free end
Of the new belt with ‘T’ shape plates & wire rope. (Refer Fig
5 & sketch-1). The rope length should be more than the height of gallery
from ground.

• Wrap the rope with a fixed and robust structure. 1. Holding of the belt
in gallery to be released. Now pulling the belt and releasing rope to be
done simultaneously. 2.The old belt should be pulled slowly and after
complete replacement of old belt, both ends of new belt to be joined
with plate fasteners (Refer Fig 6) and the joint to be
Positioned in required place for vulcanizing by using belt drive.

3. After all these activities performed & complete belt changing, power
cut off clearance to be taken and positive isolation locking to be done
properly. (Follow Safety tagging system).
4. If there is excess new belt before cutting, it should be hold with rope
and other end of rope should be fixed / anchored with robust structure
at upper level. (Refer Fig7) 5. After vulcanizing, idlers to be set in their
position release the take-up and put tension on the belt.
Once again inspection to be done to see “Is any jam angle left intact
with belt? “. If not, Job completion clearance to be given.
6.3 SAFE OPERATING PROCEDURE FOR BELT/PIPE CONVEYOR OPERATION
6.3.1 Belt/Pipe Conveyor
1. DO ensure all START/STOP and emergency controls are clearly marked.
2. DO keep the area clean and tidy. Good housekeeping

Eliminates hazards, i.e. tripping, slipping and falling.

3. DO lockout, isolate, danger tag, or use some other control measure
before working on a bogged or overloaded conveyor 4.DO isolate and
danger tag the power source before working on a bogged or overloaded
conveyor.
5. DO ensure persons working near a conveyor are aware of the location of
STOP/START and emergency controls.
6. DO wear appropriate clothing-avoid loose clothing near moving
conveyors.
7. Do not walk under a moving conveyor unless the access is guarded
against the spillage.
8. DON'T clean belts, pulleys, drum, and trough or return idlers while a
conveyor is moving.
9. DON'T ride on a moving conveyor.
10. DON'T repair or maintain a conveyor while in motion 11.DON'T
sleep on the idle conveyor.
12. DON’T have a food on the idle conveyor.
6.3.2 DANGER-NIP POINTS

The most important danger points on belt conveyors are the nip points
marked with arrows (Refer Fig No: 1.12). Any nip point that is within 2.5
meters of any walkway or access way (i.e. within reach) must be guarded to
prevent accidental
contact with nip points
6.3.3 STARTING THE CONVEYOR OPERATION

1. The pipe conveyor must not be started until the

downstream circuits are prepared to accept feed.
2. Pipe conveyor auxiliary equipment must be running before starting the
conveyor, if any (ex. magnetic separator, etc.) 3.Whenever equipment is to
be started, the operator must ensure that the equipment is ready
and no personnel
Working in the area are too close to the equipment.
 4. Ensure emergency stop switches working and clearly
marked
5. Ensure Pull cards are fitted and other safety devices are
Working correctly.
6. Check the warning siren working condition 7.Ensure firefighting devices in
place ready for use. 8. Check the lights are working and clean.
9.Sufficient numbers of Warning siren / Hooter alarm shall
Be provided. The alarm voice shall be audible to entire conveyor corridor.
6.3.4 Pre-Operational Inspection

Operators must inspect the plant visually before start-up after a complete
shutdown. This inspection to check whether activities, such as maintenance
tasks, must be performed before the start-up begins. Included in the
inspection are:
1. Incomplete or omitted repairs.
2. Tools, slings, and ladders that have not been cleared away after
maintenance.
3. Guards of rotating machineries are fixed properly
4. Locks left on equipment, and stop buttons that have not been reset.
5. General safety hazards, such as obstructions in walkways or stairways,
slippery floors, or tripping hazards.
6. Material spills. 7.
Lubrication spills.
Operators must inspect the plant visually before start-up after a complete
shutdown. This inspection to check whether activities, such as maintenance
tasks, must be performed before the start-up begins. Included in the
inspection are:
1. Incomplete or omitted repairs.
2. Tools, slings, and ladders that have not been cleared away after
maintenance.
3. Guards of rotating machineries are fixed properly
4. Locks left on equipment, and stop buttons that have not been reset.
5. General safety hazards, such as obstructions in walkways or stairways,
slippery floors, or tripping hazards.
6. Material spills. 7.
Lubrication spills.
8. Ensure that electrical power is available and all breakers in the motor
control center (MCC) for the equipment scheduled to operate are in the
 ‘ON’ position.
9. Ensure that there is sufficient material available to sustain a start-up.
10. Verify that equipment interlocks are satisfied. Ensure that the guards
are in place and secure.
11. Ensure that there are no tools or equipment between the guards and
moving parts.
12. Check the motor and other drive components for loose or damaged
parts.
13. Damage of belt in form of cuts, cracks, tearing or peeling 14.Excessive
swaying of belts on idlers
15. Wearing out of belt scrapers
16. Abnormal sounds from idlers or pulleys indicating worn out or damaged
bearings
17. Check oil levels in gearbox
6.3.5 Start Up

Start-Up from Complete Shutdown

1. Perform the pre-operational inspection. Alert other

operators to the impending start-up.
2. Ensure that the appropriate downstream equipment is started and
functioning properly.
3. Start the belt conveyor drive motor. 4.Start
the belt conveyor feed system
Start-Up from Power Failure

The procedures for starting up from a power failure differ from those after
controlled shutdowns.
In the case of a power failure, the conveyor belts shut down under load.
When authorized by supervision, proceed with the belt conveyor start-up.
Ensure that any circuit breakers that
 May have tripped during the power outage have been reset. Start the belt
conveyor using the appropriate procedure described in Start-Up Procedures

6.3.6 Shutdown Procedures

There are two primary objectives of the shutdown procedure:
• To secure equipment so damage is prevented.
• To make start-up efficient and timely.
After a complete shutdown, equipment should be inspected thoroughly and
a list of maintenance and repair items prepared. After an emergency
shutdown, a visual inspection of the equipment is required before start-up.
This section contains procedures for shutting down the belt conveyor
equipment.
 Normal Shutdown
 Emergency Shutdown

6.3.7 Normal Shutdown

Equipment could be shut down when the following conditions are met:
• Unit is shut down
No more need of material for the downstream equipment.

Normal Shutdown Procedure

1. Raise alarm for two minute
2. Slow down the speed of the conveyor gradually
3. First stop the downstream the conveyor
4. Then stop the upstream conveyor
6.3.8 Emergency Shutdown
Equipment must be shut down immediately if someone is in danger. More
frequently, the emergency is caused by an equipment failure requiring all or
part of the plant to shut down. Emergency shutdowns usually involve
shutting down upstream equipment under emergency conditions, but
downstream equipment may be shut down in a controlled manner. The
downstream equipment may be allowed to continue operating so that the
plant can return to normal
Operating conditions more quickly. If the potential for injury
 To personnel or damage to a piece of equipment exists, the equipment must
be shut down immediately.
6.3.9 Emergency Shutdown Procedure
1. Shut down the pipe conveyor using the STOP button/field safety
switches.

2. Raise emergency alarm.

6.3.10 During Operation

1. Only trained employees shall be permitted to operate conveyors. Training

shall include instruction in operation under normal conditions and
emergency situations.
2. Where employee safety is dependent upon stopping and/or starting
devices, they shall be kept free of obstructions to permit ready access.
3. The area around loading and unloading points shall be kept clear of
obstructions which could endanger personnel.
4. No person shall ride the load-carrying element of a conveyor under any
circumstances unless that person is specifically authorized by the owner or
employer to do so. Under those circumstances, such employee shall only
ride a conveyor which incorporates within its supporting structure,
platforms or control stations specifically designed for carrying personnel.
Under no circumstances shall any person ride on any element of a vertical
conveyor. Owners of conveyors should affix warning devices to the
conveyor reading Do Not Ride Conveyor.
5. Personnel working on or near a conveyor shall be instructed as to the
location and operation of pertinent stopping devices.
6. A conveyor shall be used to transport only material it is capable of
handling safely.
7. Under no circumstances shall the safety characteristics of the conveyor
be altered if such alterations would endanger personnel.
8. Routine inspections and preventive and corrective maintenance
programs shall be conducted to insure that all
 Safety features and devices are retained and function properly.
9. Personnel should be alerted to the potential hazard of entanglement in
conveyors caused by items such as long hair, loose clothing, and jewelry.
10. Conveyors shall not be maintained or serviced while in operation unless
proper maintenance or service requires the conveyor to be in motion. In
which case, personnel shall be made aware of the hazards and how the task
may be safely accomplished.

6.3.11 While conveyor belts are in motion

Dos
1.Pull the cord in case of emergency 2.Cover the tail

end of belt and drum

3.Guard the nip point between the drum and belt 4.During maintenance

obtain line clearance / work permit

5. Put the danger tags on switches when the persons working on the belts

6. If possible, walky-talky shall be used

Don’ts
1. Lubricate

2. Clean

3. Clear / load fallen materials

4. Work close to tail end drums

5. Wear loose cloths

 6. Stand close to belts

7. Sit on the belt

8. Stand below the belt

9. Weld or gas cutting near the belt

10. Do not touch the running belt, idlers etc.

6.4 SAFE OPERATING PROCEDURE FOR BELT JOINTING (HOT

VULCANIZATION)

6.4.1 Safe Procedures

1. Release to be taken from Control room and from operation dept.

2. Take the work permit from relevant authority

3. Risk assessment should be prepared and it should be explained to the

all concerns before starting of the activity

4. Isolate the system electrically & Adopt LOTO system 5.Make sure

that Breaker is in switch off condition.

6. Engage the emergency switch and Pull chord at working place.

7. Lift the counterweight up to 5 mtr with the help 10MT chain pulley
block of suitable capacity to remove the tension
 of the belt

8. Provided physical stopper to arrest the counter weight 9.Clamp the

belt at the required level.

10. Belt Clamps should to be checked & certified by site engineer

11. Make sure the belt clamps holding the belt properly.

12. Clamp to be tightened as per the torque suggested by the clamp

manufacturer (160 N/M)

6.4.2 Preparation of Working Surface

Prepare a working surface at least 3 meters long on both sides of the

vulcanizer. The Material used (Ex. square timber panel) for working surface
must be sufficient strength and stability to ensure that there is no danger of
their breaking or turning over. Make sure that there is sufficient space and
suitable power source.

6.4.3 Splicing of belt

Refer Annexure-I

6.4.4 Buffing (Grinding)

1. Grinding machine shall be ensured that the handle and body of the
machine intact.

2. The machine should be provided with wheel guard.

3. Only Depressed Grinding wheel shall be used for grinding operation.

4. Each wheel shall be run up to its maximum operating speed on the

machine under no load conditions for about 30 seconds before
commencing the work.

5. The machine operator shall ensure that the machine is

provided with wheel guard and hold the machine away from his body during
this test run, as the wheel may break if there
 Is any damage.

6. During Grinding operation excessive force shall not be used, as it would

lead to wheel breakage. The wheel shall be held at angle between150 to
300.

7. Hand held grinding machine having it’s body made of non

Conductive material is preferred.

8. It shall be ensured that the body of the machine is earthed, if

it is made of conductive material.

9. Power supply for the machine shall be through ELCB / RCCB of 30

mA sensitivity.

10. Refer Figure No:01 for Safe handling & guard provision of grinding
machine

6.5 SAFE OPERATING PROCEDURE RETURN ROLLER

REPLACEMENT

6.5.1 Safe Procedure

1. Release to be taken from Control room and from operation dept.

2. Take the work permit from relevant authority

3. Risk assessment should be prepared and it should be explained to the

all concerns before starting of the activity

4. Isolate the system electrically & Adopt LOTO system

5. Raise the take-up weight to an appropriate height (if required).

6. Make sure that Breaker is in switch off condition.

 7. Engage the emergency switch and Pull chord at working place.

8. Take return roller to the place where it is to be replaced.

9. Hang the chain pulley block (with the help of sling) to the place where
it is to be replace of return roller.

10. Lift the belt with the help of belt sling and chain pulley block.
(Hitch;- Single Basket hitch )

11. Remove the damaged return roller by opening bracket mounting

bolts from frame.

12. Take the new return roller which is to be fixed

13. Place the return roller at its place & fixed the mounting bolt.

14. Tighten the mounting bolts.

15. Down the belt with the help of chain pulley block and remove the
belt sling

16. Release & Remove the chain pulley block.

17. Make sure all tools tackles removed from work place.

18. Ensure all workmen are away from the vicinity of conveyor
movement area

19. Close the work permit & hand over to the issuing authority
with isolation tag

20. Issuing authority should check the workplace and Ensure its safe

21. Close & Give clearance to operation department 22.Take a

trial run at low speed

23. If the performance of belt is satisfactory put the system in operation.

 6.6 SAFE OPERATING PROCEDURE FOR IDLER
REPLACEMENT

6.6.1 SAFE OPERATING PROCEDURES

1. Release to be taken from Control room and from operation dept.

2. Take the work permit from relevant authority.

3. Risk assessment should be prepared and it should be explained to the

all concerns before starting of the activity.

4. Isolate the system electrically & Adopt LOTO system.

5. Raise the take-up weight to a appropriate height (if required).

6. Make sure that Breaker is in switch off condition.

7. Engage the emergency switch and Pull chord at working place.

8. Take idler to the place where it is to be replaced.

9. Hang the chain pulley block (with the help of sling) to the place where
it is to be replace of idle roller.

10. Lift the belt with the help of belt sling and chain pulley block.
(Hitch;-Single Basket hitch)

11. Remove the damaged idler by opening bracket mounting bolts from
idler frame.

12. Take the new idle roller which is to be fixed. 13. Place the idler at

its place & fixed the mounting bolt. 14. Tightened the mounting

bolts.

15. Down the belt with the help of chain pulley block and remove the
belt sling.

16. Release & Remove the chain pulley block.

17. Make sure all tools tackles removed from work place.
 18. Ensure all workmen are away from the vicinity of conveyor
movement area.

19. Close the work permit & hand over to the issuing authority
with isolation tag.

20. Issuing authority should check the workplace and ensure its safe.

21. Close & Give clearance to operation department. 22. Take a

trial run at low speed.

23. If the performance of belt is satisfactory put the system in operation.

6.7 SAFE OPERATING PROCEDURE LUBRICATION OF

CONVEYOR ROTATING MACHINERY

6.7.1 Safety Procedure

1. Release to be taken from Control room and from operation dept.

2. Take the work permit from relevant authority.

3. Risk assessment should be prepared and it should be explained to the

all concerns before starting of the activity.

4. Isolate the system electrically & Adopt LOTO system. 5.Make sure

that Breaker is in switch off condition.

6. Engage the emergency switch and Pull chord at working place.

7. Remove the guards if required.

8. Lubricate the system where ever required (all greasing

points).

9. All the Safety guards should be replaced after completion of job.

10. All the tools should be cleared from the workplace.

11. Oil contaminated cotton wastage should collected in dust bin.

12. Please ensure that the oil / grease shall not be spilled over the
movement areas.

13. Competent supervision should be ensure always.

14. Ensure all workmen are away from the conveyor movement
area.

15. Close the work permit and hand over the permit to the issuing
authority along with isolation tag.

16. Issuing authority should check the workplace and ensure its safe.
17. Close & Give clearance to operation department.
6.8 STACKER CUM RECLAIMER
6.8.1 Checklist to be followed by Operator before going to
operator cabin
1.Will ensure whether any releases have been taken for maintenance job
in stacker, clearance from shift-in-charge he will switch on the followings (if
previously switched

(a) HT Isolator
(b) PLC incomer MCB
(c ) All feeders
(d) Control supply MCB
(e) Main breaker
2. Operator will ask for permission signal for STACKING/RECLAIMING from
CCR through shift in-charge. 3.Before running any
components like boom conveyor,
Intermediate conveyor, long travel or vibro feeder, clearance to be taken for
the same from shift-in-charge.
6.8.2 Procedure of Operation

Basically there are two types of operation the machine is handling.

1. Stacking: (Coal comes from barge at coal berth jetty through several
conveyors and deposited at either side of coal yard).

2. Reclaiming: (Coal will be sent to unit bunkers with the help of bucket
wheel and through conveyors).

1. Stacking Procedure:-

a) To start the STACKING, operator will go through the checklist

mentioned above and will start BOOM conveyor in FORWARD
mode from touch screen inside cabin after selecting STACKING
mode in selector switch.

b) Then INTERMEDIATE conveyor and VIBRO FEEDER will be

started sequentially.

c) CCR will receive the signal from the machine

 Through radio modem that all the system in stacker are in
running mode, so after that YARD conveyor will be started from
CCR.

When coal will reach the stacker through YARD conveyor,

Coal piles can be created in

Either side of coal yard in two ways.

1. By LONG TRAVEL (Mostly used)

2. By SLEW OPERATION

2. Reclaiming Procedure:-

a. To start the RECLAIMING, operator will go through the checklist

mentioned above and check the indication of YARD conveyor ON
in operator cabin.
Then BOOM conveyor will be started in REVERSE mode from touch screen
inside cabin after selecting RECLAIMING mode in selector switch.
Then BUCKET WHEEL will be started.
After that reclaiming will be started from either side of coal yard and
discharge rate will be followed as per instruction from CCR.
Reclaiming can be done in two ways.

1. By LONG TRAVEL (Mostly used).

2. By SLEW OPERATION.

7. RECORDS:
7.1 Standard Operating Procedure for Belt Conveyors and Pipe Conveyors.
7.2 Standard Maintenance Procedure for Belt Conveyors and Pipe
Conveyors.
7.3 Hazard Identification & Risk Assessment (HIRA) for Operation and Maintenance of Belt
Conveyors and Pipe Conveyors.
7.4 Inspection Checklist for Operation and Maintenance of Belt Conveyors and Pipe
Conveyors.
7.5 Filled Permit to Work (SAP) PTW for Maintenance of Belt Conveyors and Pipe
Conveyors.

8. TRAINING & COMMUNICATION

All workmen, Supervisors & Engineers who work on or in the vicinity of conveyors must be
informed of the hazards they may encounter, and must receive training in established
preventive measures and work procedures.

8.1 Workmen, Supervisors & Engineers Training (Operation):-

Only competent and authorized Workmen, Supervisors & Engineers must be allowed to
start up, operate and interrupt the normal operation of a conveyor. Workers must be
trained in:
 Conveyor start-up
 Normal shutdown and the use of emergency stop devices
 Required checks for restarting a conveyor after an emergency shutdown or
accidental stoppage
 Proper loading procedures to prevent overload
8.2 Workmen, Supervisors & Engineers Training ( Maintenance)
 Assign only competent Workmen, Supervisors & Engineers who have the
technical skills to maintain conveyors. Assigned
 Workmen, Supervisors & Engineers must be informed of the conditions under
which various maintenance tasks are to be
 Completed. Workmen, Supervisors & Engineers must be trained in “Permit to
Work (SAP) System & Procedure.
8.3 Initial Communication to be done through Corporate Communication, Email and
subsequently shall be made available at safety portal at Sangam
9. VERIFICATION
9.1. Verification of implementation shall be done during Permit-To- Work (SAP)
(PTW) procedure audit, field safety visit, site inspection and Operation and
Maintenance Checklist.

10. EXEMPTION:
10.1. Design of conveyor systems are not within the scope of this procedure
10.2. Any exception to this procedure need to be approved by Chief – Corporate
Safety.

11. REFERENCES

11.1. O & M Manual of Belt Conveyors.

11.2. O & M Manual of Stacker Reclaimer
11.3. O & M Manual of Pipe Conveyors.
11.4. IS 7155-8 (1994) Code of recommended practice for Conveyor Safety
11.5. Permit to Work System
11.6. LOTO Procedure
11.7. Job Safety Analysis (JSA) Procedure
11.8. Hazard Identification & Risk Assessment (HIRA) Procedure
(OHSAS 18001:2007)

REVIEW: - Review of this procedure shall be done as and when but not later than once in
every three (03) years. Typical Factors like Changes in legislation, Recommendation from
OEM, Feedback from users of other Coal Fired Power Plants, Review of Incident Reports,
Inspection & Audit findings, Recommendations in Incident investigation reports may be
inputs for the review and revision of the procedure
12.

1.1) Table-2 Table for selection of Jam angle

1.2) Table-3 Table for selection of belt fasteners

1.3) IS 7155-8 (1994) Code of recommended practice for conveyor safety

 Compressed air system
TABLE OF CONTENTS

INTRODUCTION.............................................................................................................2

1. GENERAL..............................................................................................................2

2. TOOLS, FITTINGS AND EQUIPMENT....................................................................2

3. PERSONAL PROTECTIVE EQUIPMENT (PPE) AND CLOTHING..............................4

3.1 EYES.................................................................................................................4
3.2 HANDS.............................................................................................................4
3.3 BODY...............................................................................................................4
4. SAFE USE OF COMPRESSED AIR...........................................................................4
 INTRODUCTION
This guide manual provides information on the safe use and protection of personnel
when using compressed air.

1. GENERAL
Compressed air is an energy source, used throughout industry for various purposes. As an
energy source it must be treated with the same respect as electricity, if it is not used
correctly it can be fatal.

Compressed air may be stored in cylinders and air receivers or generated by compressors.
Air under pressure is delivered via a regulator, air-line and air hoses to air tools and
equipment. The tool or equipment is driven by the energy contained in the compressed
air.

2. TOOLS, FITTINGS AND EQUIPMENT

! WARNING

No plant air is to be used on any process associated with abrasive blasting or

industrial coating (breathing, blasting or painting)

Observe the following precautions when using compressed air:

 Select equipment suitable for the pressure being used.

 Select air hoses according to AS/NZS 2554:-1998 - Hose and Hose Assemblies for Air.

 Ensure that air hoses and connectors are in good condition.

 Secure all fittings in the approved manner e.g. use safety clips in all snap coupling joints,
attach chains to screw coupling.

 Before use check all couplings for damage that might prevent a connection or proper seal.

! WARNING

Do not use damaged or worn fittings and equipment.

 Ensure the trigger or operating valve works properly. If it is faulty, the equipment shall be
removed from service. Repairs shall be undertaken by a competent person before the
equipment is placed back in service.

 An Out of Service Tag is to be used to tag out any faulty equipment. Report the fault to your
group leader or the person responsible for the equipment to have it repaired.
 Before disconnecting tools, depressurize the airline by isolating at the main air supply
valve and operating the connected tool until all the air is expelled.

 Always isolate the air supply at the main air valve when not in use, and depressurize airlines.

 Always drain water traps or reservoirs before using airlines or compressors.

 Never kink a hose to stop the air supply, close the valve.

 Air break (excess flow cut off) valves should be considered for installation in main compressed
air-line supply to air hoses. If an air break valve has not been installed, secure the hose to
prevent whipping in the event of failure.

 Airline outlets shall be positioned to prevent any person being exposed to a direct blast of air.

 Isolate and bleed all compressed air equipment before dismantling,

 Always point air guns away from the user and NEVER directly at anyone else.

 Never use compressed air to pressurize a vessel (unless the vessel is specifically designed for
that purpose). For example, do not use compressed air to empty oil from gear boxes. They are
not designed to withstand high internal pressures.

! WARNING

Accidents have happened in which personnel were killed because gear boxes exploded
under pressure

 Do not dry bearings using compressed air.

! WARNING

There have been incidents where bearings have exploded because of the excessive
speed of rotation caused by drying with compressed air.

 Compressed airlines shall be labelled in accordance with the AS 1345 - 1995 Identification of
the Contents of Pipes, Conduits and Ducts.
 3. PERSONAL PROTECTIVE EQUIPMENT (PPE) AND
CLOTHING
Wearing appropriate personal protective equipment and clothing can reduce
compressed air injuries.

3.1 EYES

 Wear goggles when using compressed air.

 Wear a face shield where there is a risk of flying particles.

! WARNING

Safety glasses worn beneath a face shield do not provide adequate eye protection
goggles must be worn.

3.2 HANDS

Wear gloves that the compressed air cannot penetrate, such as rubber or leather.

3.3 BODY

Use leather or PVC or similar aprons where there is a risk of contact with compressed air.

! WARNING

Cotton clothing is not a barrier to compressed air.

4. SAFE USE OF COMPRESSED AIR

! WARNING

Do not play practical jokes or be involved in horseplay with compressed air – it can
be fatal

Observe the following precautions when using compressed air:

 Always wear appropriate personal protective equipment and clothing (refer to section 3 -
PPE and Clothing).

 Never use compressed air to dust off clothing. There is a risk of injury to eyes, perforation of
the eardrums, and penetration of the skin, leading to bubbles in the blood stream and
possible embolism, causing death.
 Do not use compressed air to clean up your work area. This can create airborne particles that
will put you and others at risk of injury,

Note: Where it is considered that compressed air must be used to blow-down or clean
hard to get at places etc., and it is impractical to use some other, safer, means
such as vacuum cleaning, compressed air maybe used provided compressed
outlet air pressure does not exceed 200 kPa and a task risk assessment is carried
out with strict precautions are taken to protect the user and persons in the
vicinity.

 Do not try to stop a whipping hose. The force of the hose can break bones. Isolate the air at
the main valve and wait for hose to settle.

 Do not create trip hazards with air hoses. Suspend or guard hoses with boards.

 Isolate and bleed all air-lines and hoses before disconnecting. To disconnect air-lines under
pressure is hazardous.

 Use compressed air only for the work it is provided for. It is an energy source and must be
treated as such.

TABLE OF CONTENTS

INTRODUCTION
 1. How are wastewater workers exposed to chemicals or diseases?

2. What kind of exposures occur for different kinds of treatment processes?

3. What about exposure to other materials in wastewater such as metals, radioactive

compounds, or asbestos?

4. Do workers exposed to chemicals for short periods of time show any adverse
health effects?

5. Do wastewater workers show adverse health effects from chemicals after

years on the job?

6. Do wastewater workers experience any adverse effects upon their

reproductive function or upon their offspring?

7. Are workers exposed to diseases by inhalation?

8. What kinds of diseases are wastewater workers exposed to?

9. Do treatment processes reduce or kill disease-causing organisms?

10. How can we find out whether wastewater workers are exposed to disease?

11. Do wastewater workers actually get sick from disease exposure at work?

12. What about the risk of contracting hepatitis B or AIDS?

13. Can a worker get a disease from an accidental exposure, such as sewage
splashed into the mouth?
Is the disease risk really so low?

14. Do wastewater workers develop allergies, other than reactions to

endotoxins or mycotoxins?

15. How can exposure to chemicals and disease be reduced?

16. Should a wastewater worker be immunized to reduce the risk of infection?

17. Are there adverse health effects from chronic exposure to low levels of
Hydrogen sulfide gas?

18. What medical surveillance is recommended for the wastewater worker?

WATER AND WASTEWATER TREATMENT WORKERS

Introduction

Sewage is the used water of a community and can include domestic wastewater and
industrial wastewater. Combined sewer systems will include storm water such as road
runoff which carries oils, salts, metals, and asbestos. Many systems, especially older
ones, will receive infiltration which can carry pesticides and herbicides from soil
application.

For many years, work in the wastewater treatment field was considered the most
hazardous, especially due to deaths involving confined space entry.
This field is considered somewhat less hazardous today, but treatment plant workers still
do experience health problems and deaths. These experiences occur in specific incidents
involving chemicals in the sewer system and in regular work exposures throughout the
plant and its processes.

Some chemically-related health complaints are acute in nature, involving short-term

exposures and complaints such as irritations of the eyes, nose or throat. Other
problems are chronic in which repeated exposures, sometimes over several years, have
caused effects upon internal organs or have involved occupationally-related allergies.

Studies have shown that wastewater treatment may generate aerosols containing
microbiological and chemical constituents. In fact, the primary route of exposure for
workers is probably inhalation. The physical layouts of many sewage treatment plants
involve open tanks and basins; plants typically are not designed to prevent aerial
dispersion of wastewater during the treatment process. Volatile organics in wastewater
may be vaporized or air-stripped during treatment. Many of the compounds are
carcinogens and/or mutagens, so sewage workers may be at increased risk of cancer or
adverse birth outcomes.

Infections from exposure to waterborne disease organisms may be subclinical or may

appear as actual disease in wastewater workers.
Treatment personnel have reported nausea, vomiting, indigestion, diarrhea, and flu-
like complaints. Studies of antibodies in the blood of workers have documented that
disease exposures have occurred.

Although several years of exposure tends to produce eventual immunity for many
workers to some organisms, new workers tend to be ill more often than experienced
workers.

This manual examines how exposure occurs during the treatment processes; ways to
reduce exposure by engineering controls, administrative controls, process control
strategies, and protective equipment; and some suggested medical surveillance.

A single sewage treatment plant may service a hundred or more industries; therefore an
enormous range of chemicals may be present in the influent and sludges. The presence
of toxic chemicals and organisms in sewage, in sludge, and in the air at specific sites in
sewage plants has raised suspicion regarding their possible effects on the health of the
workers in these plants.

Wastewater treatment plant workers may be exposed to chemicals or organisms by

direct contact with wastewater and sludges, or by inhalation of gases, particles, aerosols,
vapors, or droplets. These hazards may enter the plant in soluble form or attached to
suspended solids. Compounds reported from sludge analyses include chlorinated organic
solvents and pesticides, PCBs, polycyclic aromatics, petroleum hydrocarbons, flame
retardants, nitrosamines, heavy metals, asbestos, dioxins, and radioactive materials.
The concentration of organics and metals in sludge is indicative of the areas’ industries;
for example, high concentrations of PCBs in Schenectady,
NY, sludge was due to the manufacture of electrical equipment upstream from the
treatment plant. There are also derivatives of chemicals formed by microbiological or
other processes during the sewage treatment process; these may be more or less toxic
than the original compound. Disease- causing organisms have been found in sewage
sludge; therefore, sewage workers may be at increased risk of infection or diseases.
1. How are wastewater workers exposed to chemicals or diseases?

INHALATION appears to be a major route for chemicals or organisms to enter the body.
Some chemicals are air-stripped from wastewater and workers working near weirs,
aerated tanks, dewatering processes, and other sludge processes (drying, compacting,
and incineration). Aeration and dewatering processes also put droplets and particles
into the air which can be inhaled. Much of the material inhaled into the throat or
bronchial tubes is cleared from the lungs and swallowed. As a result, respiratory and
gastrointestinal exposure can occur from inhaled chemicals and organisms.
Wastewater workers have also been exposed to chemicals while attempting to remove
these substances from treatment plant equipment.

SKIN CONTACT is also a route of entry for both chemicals and disease. Chemicals can
be absorbed through the skin from contact with wastewater or sludge. Disease
organisms can also enter the body through cuts or abrasions. There has also been a
report of a wastewater worker who received a needle stick injury when removing
screenings from a bar screen.

2. What kind of exposures occur for different kinds of treatment

Processes?

THE POTENTIAL FOR INHALATION IS DETERMINED BY THE WATER—SOLUBILITY

OF A CHEMICAL.

When air is passed through water, or if that water is splashed into the air, some
chemicals will be removed from the water and transferred into the air: this is called air-
stripping. Chemicals which tend to be very soluble in water are more likely to be air-
stripped from pure water or natural waters; as, for example, during aeration of drinking
water. However air-stripping does not appear to occur quite so readily from wastewater
because water insoluble compounds tend to attach to sewage solids. As a result, in
sewage, compounds which are somewhat water-soluble appear to be air- stripped early
in the process, such as from the grit chamber weir, primary clarifier weir, or during
aeration in the grit chamber itself. Compounds which are very water-insoluble tend to
be released to the atmosphere during
Later treatment steps such as aeration in the activated sludge process. If a volatile
chemical is biodegradable, its emission may be even higher from the primary clarifier
weir than from the aeration basin where it is biodegraded rather than sir-stripped.
Emissions from the weir are higher than from the clarifier surface.

This is important to the wastewater worker because it means that the water- soluble
compounds will stay in the plant longer since they are attached to sludge. If a wastewater
treatment plant tends to receive periodic slugs of fairly water-soluble organic chemicals,
then covering the grit chamber weir (with ventilation for worker entry) may significantly
reduce water exposure. Other alternatives include the collection and treatment of the
off-gas; the use of holding tanks for the hazardous influent and reserving it for further,
more specialized treatment such as wet-oxidation; or the addition of activated carbon to
the wastewater to absorb these chemicals and prevent their air-stripping.

The water-insoluble organic chemicals which attach to sludge solids are returned to the
head of the aeration basin (return activated sludge); thus, these materials may actually
spend a considerable time in the facility, depending upon the sludge age. So, when a
slug flow of a hazardous chemical is received, one cannot simply assume that volatile
chemicals will be released only during the time required for the slug flow in the main
wastewater stream to pass through the plant. Absorption onto sludge solids keep these
materials in the plant for a much longer period of time and thus prolongs their release
to the atmosphere. In terms of process control, air- stripping may be increased by
increasing the aeration rate. On the other hand, maintaining higher concentrations of
suspended solids in the system may slow the stripping rate, and thus lower the
concentration of volatiles above the aeration basin, but lengthens the duration of the
air-stripping.

When air-stripping occurs, the volatile chemical moves from an area of higher
concentration (the sewage) to one of lower concentration (the air) until the air becomes
saturated (that is, when the air holds as much chemical as it can). In the activated
sludge process, the air-stripping of volatile organic chemicals seems to be greater in
surface aeration systems than inBubble aeration systems. The reason seems to be that
in the surface aeration system, there is so much air flow above the basin that the air
stream doesn’t get the chance to become saturated, so there is virtually no limit on the
stripping rate. Pure oxygen plants with covered aeration basins tend to be rather
inefficient for the stripping of volatile compounds. Trickling filters with forced aeration
are quite efficient for air-stripping.

In the bubble aeration system, the stripping rate is limited since the air bubbles quickly
become saturated. Even if volatile chemicals are still available in the sewage, no more
can be stripped. For bubble-type systems, stripping is more efficient for coarse bubbles
than for fine bubbles. During bubble aeration, only a few percent of the air dissolves in
the mixed liquor, most of the air escapes to the atmosphere as bursting bubbles. These
bursting bubbles cast droplets into the air which evaporate to produce solid particles.
Aeration also causes rolling motions of the mixed liquor and this splashing is another
source of aerosol droplets. Studies of bursting bubbles have shown that about 40% of
the particles from aeration are less than 10 microns in diameter and so they can be
inhaled.

Aerosol formation and air-stripping may also occur at the treatment plant outfall; these
may include the release of chloroform. To estimate the risk of disease from the aerosols
of the plant effluent, it may be possible to draw upon studies of workers exposure to
aerosols at wastewater land spraying sites.
So far we have dealt with chemicals coming down the pipe to the treatment plant, but
we can actually produce some volatile chemicals ourselves within the water or
wastewater treatment process. For example, when chlorination is used for disinfection
or for odor control, humic materials in water or wastewater can react with chlorine
(especially hypochlorous acid, HOC1) to form chloroform. Although chloroform is the
major product, other chlorinated and no chlorinated breakdown products of humic acids
can be generated as well. Chloroform generation can be eliminated by considering
alternatives to chlorine. Odor can also be controlled by using hydrogen peroxide or
potassium permanganate.
Aerosol droplets are produced by aeration processes through the breakup of tiny water
jets formed by the collapse of bubbles. When a bubble breaks, it ejects a droplet that is
about one-tenth the diameter of the of the bubble which produced it. This process
causes bacteria and viruses, as well as chemicals, to be ejected into the air. If the
wastewater surface has an oily film, then the aerosol droplets also will have an oil film.

Aerosols and air stripping could also occur during some dewatering processes.

3. What about exposure to other materials in wastewater such as

metals, radioactive compounds, or asbestos?

Metals are generally not air-stripped into the air in sufficient quantities to be significant.
Metals tend to either accumulate in sludge or pass-through into the receiving water.
Metal removal by activated sludge reflects not only the metals behavior in solution, but
also the sludge age and whether the plant is acclimated to that metal. Metals are
absorbed by activated sludge because they are attracted to the active sites of the floc’s
biopolymers. A a result, the metals content of waste activated sludge tends to be
approximately 2 - 5
Times that of primary sludge.

• Case history: mercury emissions

Mercury is a possible exception that may be air-stripped if it is present in the
wastewater in sufficient concentrations. Mercury in the air has been studied at
wastewater treatment plants including Utica, New York, Air concentrations varied
enormously in this study since the plants receive different kinds of mercury
compounds; but some plants did have organic mercury emissions above EPA limits.

For radioactive materials, it is useful to compare the half-life of the element to the
plant’s sludge age to approximate the wastewater worker exposure.
Radioactive elements with short half-lives may be more hazardous to the worker since
the element will be undergoing decay while it is in the plant. For a material with a long
half-life, relatively little decay will be occurring
While that material is present in the wastewater or sludge. Radium appears to be
effectively removed by activated sludge as well as by fixed growth biological
treatment systems such as trickling filters or RBCs. Volatile radioactive compounds
may be air-stripped.Some sources of radioactive materials to be aware of include: O
Medical and industrial wastes released to sanitary sewers.
O Releases from medical treatment and research, including excretion by patients (for
example, iodine - 131; 8-day half-life)
O Unauthorized releases from manufacturers, including NRC licenses O Water
treatment sludges from drinking water containing elevated
Concentrations of radium. Where this drinking water is treated by ion exchange, back
flushing of the columns may be discharged to sewers.
Asbestos has been found in sludge samples from treatment plants across the
U.S. The health effects are difficult to assess, but are probably minimal while sludge is
relatively wet. The risk of inhaling fibers may exist for handling and bagging of dried
sludge or possibly compost used for horticultural work or sold as fertilizer.

4. Do workers exposed to chemicals for short periods of time show any

Adverse health effects?

Yes. As we saw above in air-stripping, the fate of inhaled materials also depends to a
great deal on their solubility in water. Highly soluble gases and substances dissolve in
the mucous membrane lining of the nose and throat resulting in irritation of the upper
respiratory tract. In high concentrations, this may be noticed by the worker almost
immediately.
Upper respiratory tract irritation is almost always accompanied by eye irritation as
the materials dissolve in the fluid coating the conjunctiva membrane of the eye. Less
soluble gases result in irritation of the deeper structures of the lungs. Very poorly
soluble substances may pass directly from the inhaled air into the blood stream and
result in systemic poisoning or anesthetie effects if the agent can cause central
nervous system Depression. As a result, the insoluble gases have little or no effect on
the organs of respiration but may produce severe systemic toxicity. So, materials
which might not cause irritation would not alert the worker to their presence, but
could cause serious health effects.

Wastewater workers have been exposed to chemicals in acute (short-term) episodes. In

fact, in some cases, it was the workers’ reports of health effects which alerted the plant
that something unexpected was being discharged to the treatment facility.

• Case history: Morris Forman WWTP, Louisville, KY. Acute exposure of

wastewater workers to an unauthorized discharge to the municipal
sewer of hexachlorocyclopentadiene (HCCPD), an intermediate in
pesticide manufacture. When an unidentified material entered the plant,
workers noticed an objectionable and odoriferous, sticky, viscous
material collected on the bar screens and grit collectors. When workers
tried to remove it with steam, a blue haze formed which spread
throughout the primary treatment area and sent 20 of the workers at
the primary plant receiving industrial sewage to the hospital. Of these
workers, 74% experienced central nervous system symptoms such as
headache, lightheadedness, fatigue, and increased need for sleep from
exposure to benzene, toluene, and other organic solvents.

• Case history: North Wastewater Treatment Plant; Memphis,

Tennessee. Similar exposure to the Morris Forman plant (above).
Industrial discharger producing and using chlorinated organic chemicals
for synthesis of flame retardants and pesticides (especially isodrin,
endrin, chlordane, and heptachlor). Workers at the treatment plant
complained of respiratory distress, dizziness, headache, and irritation of
the eyes, nose, throat, lungs, and skin when an intense chemical odor
was present One night a pesticide spill occurred and six workers
experienced severe headaches, nausea and loss of equilibrium. Air
samples at the wet well and grit chamber confirmed the presence of
these chemicals. Urine specimens of plant employees showed that they
had inhaled them.
5. Do wastewater workers show adverse health effects from
chemicals after years on the job.

There is little information on this so far.

■ Case history: Water and wastewater worker exposure has also been
studied by testing worker urine for the presence of mutagenic
substances. In one such study, the frequency of urinary mutagens was
measured in water and wastewater workers employed in 14 plants in
NYS processing 3 - 10 mgd. The results indicated that a higher frequency
of mutagens was present in wastewater workers as compared to water
treatment workers, suggesting a higher frequency of exposure to toxic
chemicals. This may mean a higher risk of adverse health effects (e.g.,
cancer and birth defects), but it is difficult to assess the health
significance. The measurement of mutagens in urine at one point in time
may not reflect worker exposure on a daily basis or overall. The presence
of mutagens as determined by a bacterial assay does not establish that
mutations are taking place in human cells or that cancer might ultimately
result.

■ Case history: Bloomington, Indiana, municipal sewage treatment

plant. For example, in a case study of a trickling filter plant, when
appreciable quantities of PCBs are present in raw sewage, significant
quantities can pass through the plant into the effluent. But, because PCBs
are not very soluble in water, they mostly tend to concentrate in sludge
and in the sediment of the receiving stream. They can bioaccumulate in
fish making it inedible and can accumulate in soil fertilized with PDB-
contaminated sludge. PCBs adsorb readily onto silt particles and solids,
therefore, bottom materials in sewers may be expected to contain
appreciable quantities of adsorbed PCBs. Workers without gloves and
handling PDB-contaminated sludge, have absorbed enough PCBs through
their skin that their blood levels of PCBs resembled the levels found in
people working in the PCB manufacturing facility which was sending the
PCBs to a treatment plant.

Sewage sludge and sewer lines contaminated with waste PCBs from electrical capacitor
manufacturing plant. Gardeners, farmers, and wastewater workers exposed to PCB-
contaminated sludge showed that Blood serum PCB levels increased with the percentage
of garden care performed by the sludge user and decreased with the wearing of gloves
while gardening. Six workers at the sewage treatment plant had levels of 6ppm (lipid
basis) compared to national surveys in which 5% of the population show levels higher
than 2 ppm.

■ Case history: Study of mutagens in municipal sludges from 34

American cities (including Buffalo, NY). Thirty-three exhibited positive
mutagenic response. Seventy-six percent of the positive responses
required metabolic activation, indicating that the sludge materials are
converted to mutagens when taken into the body.

■ Case history: Study of mutagens in municipal sludge from

Chicago, Illinois. Three species of organisms showed mutagenic
responses when exposed to the sludge.

Mortality study: Copenhagen, Denmark. Wastewater workers showed increased

mortality in first year of retirement from cancer of pancreas as most common form
 of death. The wastewater treatment plants studied serviced chemical
manufacturing plants. This was, however, a small study of the population.

■ Mortality Study: Metropolitan Sanitary District of Greater Chicago,

Illinois. This wastewater treatment plant worker study showed no
increased occurrence of cancer overall or other particular causes of
death; but there were too few workers in the study to evaluate
trends for specific cancers.

■ Mortality study: Buffalo Sewer Authority, Buffalo, New York. This

wastewater treatment plant worker study indicated that there may
be some increased cancer risk overall, but no specific cancer sites
were pinpointed.
6. Do wastewater workers experience any adverse effects upon their
Reproductive function or upon their offspring?

Little is known about reproductive effects in wastewater workers. A study was

conducted for an oil company treatment plant which looked at miscarriage rates among
the wives of wastewater workers to see if there was any work-related effect due to the
father’s exposure. Pregnancy outcomes were studied in 101 wives of sewage workers
and suggest risk of fetal loss increased among sewage workers exposed around the time
of conception; but these conclusions have been challenged since higher fetal loss
normally occurs with increasing age of mothers under 40 years of age. Also, recall bias is
a problem since the worker-exposed birth outcomes occurred from 1976-80, whereas
the unexposed group was 1934-80. This study also involved sperm count and sperm
morphology among men working throughout the refinery which showed no differences
from the wastewater plant workers. A recent study published in 1991 looked at
reproductive outcomes in fertility in male wastewater treatment plant workers and their
wives, as well as evaluating sperm and semen in the workers. The results were
compared to water workers and their wives. Spontaneous early fetal loss did not appear
to be related to wastewater exposures.

7. Are workers exRosed to diseases by inhalation?

Inhalation itself may lead to a respiratory infection or the respiratory mucous laden
with trapped pathogens may be swallowed so that the infection actually occurs in the
digestive tract. Aerosols might contaminate food or water and lead infection in the
digestive system. Organisms which can infect the lungs include M mycobacterium
tuberculosis and some of the enteric viruses. It is difficult to study health effects from
aerosols since the treatment plant is located within the area it serves: the ultimate
sources of
The pathogens in the aerosol are infected individuals in the service area. It is difficult to
determine if the route of transmission for a disease was wastewater contact or contact
with other people.
The amount and survival of microorganisms in wastewater aerosols depends upon the
amount of the organism in the wastewater, aeration basin, or
Sludge; the amount of material aerosolized; what happens to the aerosol
while in the air (such as drying of moisture or impact with a surface); and
the die-off of the organisms with distance in the downwind direction.
Even when these circumstances are known, interpreting the health risk
from the information is difficult since it is necessary to consider what is
the quantity of a particular pathogen required to start an infection in
people.

Bacteria and viruses are not necessarily evenly distributed throughout a

liquid, but can concentrate in the in the surface microlayer. This affects
how many organisms can be put into the air. During aeration, when air
bubbles break at the air-water interface, microorganisms are ejected into
the atmosphere. The bacterial concentration in the ejected drops from
bubbles may, depending upon the drop size, be from 1 to 1000 times that
of the water from which the bubbles burst.

Wind is the most important environmental factor that determines the

aerosol spread of the pathogens. When in an aerosol, the surviva1 of the
organisms depends upon relative humidity, temperature and sunlight.
These factors cause a die-off of microorganisms: the indicator organisms
appear to be affected by this shock of aerosolization than are the
pathogens, (Pseudomonas, Streptococcus, Clostridium perfringens,
Mycobacterium, and enteric viruses.

Typically, indicator organisms are used to indicate the possible presence of

associated pathogenic bacteria and human viruses because the pathogens
are difficult to assay and seldom occur at readily detectable concentrations.
Studies have shown that there can be a very poor correlation between
pathogens and indicator organisms. Also, changes in indicator organisms
may not relate to changes in pathogen concentrations. Fecal streptococcus
may be a better indicator for aerosolized wastewater. The measure of the
spread of pathogens by aerosols can be done rapidly and inexpensively by
monitoring cyanophages, viruses that attack the blue-green bacteria
(cyanobacteria). The LLP-cyanophages are not fecal organisms but may be
good indicators of water pollution since they appear in polluted water
when pathogens are present, survive longer than pathogens (more
resistant to chlorination than coliforms), and are detected by a simple test.
Diffused
Aeration activated sludge causes little aerosol release of cyanophages in
comparison to the mechanical aeration.

A trickling filter also produces aerosols while the filter is in operation; the more filters a
plant has, the higher the bacterial content of the air downwind of the filter. A study
showed that both coliform bacteria and total organisms are higher in the air at night than
during the day, showing the effect on bacterial death. Higher airborne levels of organisms
were present when the relative humidity was above 35% or during high wind speeds.

8. What kinds of diseases are wastewater workers e•R sed to?

The waterborne diseases include viruses, bacteria and protozoa (parasites) causing a
variety of conditions including:

Disease Agents

1. VIRAL
Gastroenteritis Enteroviruses (67 types), Rotaviruses,
(“24-hour flu”) Parvoviruses, Reoviruses, Astrovirus,
Calcivirus, Norwalk agent
Infectious Hepatitis Hepatitis A Hepatitis B (see text for case
history)
Serum Hepatitis (cirrhosis, liver cancer)
Aseptic Meningitis Coxsackiviruses, Echoviruses
Respiratory Disease Adenoviruses (31 types), Reoviruses,
Coronavirus
Poliomyelitis Polioviruses

II. BACTERIAL
Salmonellosis, Typhoid Fever Salmonellae (approx. 1700 types)
Shigellosis Shigellae (4 spp.)
Cholera Vibrio cholerae
Gastroenteritis Escherichia coli (enter pathogenic types)
III. PROTOZOAN
Amoebic Dysentery, Ameobiasis Entamoeba histolytica
Giardiasis Giardia lamblia
Balantidiasis Balantidium coli
Meningoencephalitis Naegleria fowleri
Acanthamoeba

BACTERIAL diseases are common to most countries; differences tend to be in the form of
additional types of bacteria and a higher incidence in wastewaters in developing or
tropical countries. Those bacteria sufficiently prevalent to be of concern in developed
nations are Samonella, enteropathogenic Escherichia coli, Shigella, and Yersinia; and to a
lesser extent Legionella and Leptospira. Samonella and E. coli are always found in
sewage and sludge. Salmonella is present in domestic animals; only Salmonella typhi
(typhoid) lives in man only. Shigellae (dysentery) is essentially exclusively a human
disease. Vibrio cholerae (cholera) survives in water for only a short time; epidemics
associated with contaminated drinking water show recent contamination. Shigellosis is
the second most common enteric bacterial infection observed in the U.S.A. In 1976, the
incidence rate for shigellosis was 6 per 100,000; salmonellosis at 11 per 100,000.

LEGIONELLA has been isolated from the water in the cooling towers of air conditioning
units in association with disease outbreaks, suggesting that disease in man results from
exposure to aerosols containing the organism.
Wastewater-exposed workers and the neighbors of treatment plants have not shown
that exposure posed a risk of infection.

SALMONELLA: The Cincinnati-Chicago-Memphis study showed higher levels in wastewater

workers; especially among inexperienced workers in Memphis.

YERSINIA: A study of sewage workers in Manitoba did not reveal a wastewater-

exposure effect.
BACTERIAL ENDOTOXINS: Toxins released from the cell walls of gram-negative
bacteria after their death can produce fever and chest- tightness in exposed
individuals. This appears to be a problem during
sludge heat-treatment operations for sludge drying, at land application sites, and at
composting operations. Individuals exposed to composted sludge in Philadelphia and
Washington, D.C., showed higher antibody levels to compost-derived endotoxin.

HEPATITIS: Hepatitis A requires serological (antibody) analysis since most infections

are subclinical and are not manifested as overt disease. Hepatitis B is a major
unconquered disease: some 200 million people are chronic carriers of the virus and a
significantly minority of these go on to develop cirrhosis or cancer of the liver. There
are reliable diagnostic procedures and a vaccine. Hepatitis B is transmitted via blood
or blood- contaminated materials; blood from skin and wounds or sores; tattooing
acupuncture, or ear piercing without rigorous sterilization of equipment. Recent
evidence indicates that sexual transmission is possible; semen and other genital
secretions can transmit the virus; and saliva also contains the virus. There are strict
disposal procedures for contaminated materials.

AIDS: The Aids virus does not appear to survive outside the body. For infection to
occur, considerable numbers of viruses must be involved. For example, of 1100
hospital workers who have experienced needle punctures with AIDS-contaminated
materials, only 2 have developed antibodies and these involved deep intramuscular
puncture wounds. For AIDS to be transmitted via sewage would involve blood in the
urine or feces of the infected individual to be discharged in the sewer. Infection would
have to involve contact of this material with cuts or broken skin. The AIDS virus may
live for an hour in blood specimens kept at room temperatures which are close to body
temperatures; otherwise, the virus seems to die off at cooler temperatures. This
would seem to mean a low chance of survival in the sewer system. As with hepatitis B,
there are strict disposal procedures for contaminated materials.

NORWALK VIRUS is largely associated with epidemics of gartroenteritis in older

children or adults. Infections are infrequent (<5%) in children under 10 years; 50 - 60%
of adults have serological evidence of infections.
 • Case history: Manitoba wastewater treatment plant workers showed a higher level of
antibody to reovirus, an enteric virus.

° Case history: Cincinnati, Ohio; Chicago, Illinois; and Memphis, Tennessee (Cincinnati
group included sewer maintenance workers). Antibody levels detected were less than
those expected: 9 of the 10 significant differences in antibody levels were higher for the
more exposed workers for both contact with wastewater and/or sludge and exposure to
bacterial aerosols. The levels of Norwalk agent antibody were higher in workers with
high and medium aerosol exposure than in low aerosol exposure. Black workers showed
higher levels of antibody to Norwalk agent and to hepatitis-A than white workers.
Although studies showed little risk of viral infections in wastewater workers; when the
results were analyzed by degree of exposure within worker groups, antibody levels for
enteroviruses and Norwalk agent suggested a wastewater effect; and antibody for
echoviruses 3 and 6 were higher in exposed workers.

• Case history: Anchorage wastewater workers showed a prevalence

of antibodies to three respiratory viruses (adenovirus, parainfluenza
type 1, and influenza type A); a possible sewage exposure-re1ated
effect.

• Case history: Bucharest wastewater workers showed a prevalence of

antibodies to three respiratory viruses (adenovirus, parainfluenza
type 1, and influenza type A); a possible sewage exposure-related
effect.

• Case history: Copenhagen sewer workers: hepatitis-A antibody

found more often than among other workers; limited risk of enteric
infection due to municipal sewage exposure.

PARASITES: The major threats of disease transmission through sewage are

Entamoeba histolytica (dysentery) and Giardia lamblia (giardiasis). Amebiasis is probably
the most common fatal parasitic infection in the USA; 1.35 cases per 100,000 in 1976.
The most common protozoan parasitic disease in USA is Giardia lamblia. Waterborne
epidemics tend to occur via contamination of the local water supply by sewage
infiltration into water distribution system. Antibody studies may not be the best
approach
For studying parasitic infections in populations since antibodies may not appear in
the blood of individuals whose stools indicate infection.

• Case history: Rennes, France. Higher Entamoeba histolytica and

Giardia intestinal is (G. lamblia) concentrations were found in
stools form sewer workers.

• Case history: Hamburg, W. Germany. Sewage workers showed an

increased infection rate for Entamoeba coli, Endolimax nana, G.
lamblia, and all protozoa combined. An incident occurred in
Hamburg in which a wastewater worker developed an amebic liver
abscess attributed to swallowing wastewater. The authors of these
studies feel that consideration should be given to the recognition of
amebiasis and giardiasis as occupational diseases for wastewater
workers.

FUNGI: Aside from the composting risk discussed below, fungi are not potentially
pathogenic to man in the same context as bacteria, viruses, and parasites. Some species
have been implicated as secondary agent of disease, as agents of hypersensitive
reactions, and as producers of mycotoxins from composting or sludge heat-treatment
operations or at land application sites. The potential risk for sludge composting workers
is for fungal spores of Aspergillus fumigatus inhaled into the lungs. Compost-exposed
workers from Washington, D.C., and Philadelphia showed a consistent increase in
antibody to this mold.

EFFECT OF TREATMENT ON PATHOGEN CONCENTRATIONS AND SURVIVAL.

As effluents become cleaner, the volume of treatment by-product has increased in direct
proportion. Since sludge is composed of the materials removed from liquid waste as it
progresses through various treatment processes: the cleaner the effluent, the more
contaminated the sludge.
Fate of Pathogens:

WORKER EXPOSURE AND INFECTION/DISEASE

Workers may be exposed by (1) inhalation of wastewater aerosols, by (2) direct contact
with wastewater or with sludge, by (3) ingestion of food or water contaminated with
wastewater or sludge (or accidental ingestion of wastewater or sludge itself), or (4) cuts,
punctures, etc. contaminated with wastewater or sludge. Infection with an enteric
organism can be CONFIRMED by the worker’s medical history or by showing that more
of the disease organism is shed in the feces than was originally received by the worker;
or infection can be INFERRED if the worker begins to produce antibodies against the
disease.

There is little data that indicates that workers or nearby residents to a plant have
actually become ill because of inhalation of pathogens in wastewater aerosols or form
other wastewater/sludge contact, even though waterborne diseases are certainly
transmitted via the contamination of drinking water with sewage. Some studies are
controversial as to whether sewage workers are at a higher risk of various
infections/diseases than the general population. Moreover, exposure to wastewater
aerosols occurs at home, since the household toilet generates aerosols when flushed.
Workers engaged in sewer maintenance and wastewater treatment are exposed to a
wide variety of routinely found disease-producing microorganisms, but, in spite of this
exposure literature searches have revealed little evidence of occupational health
problems associated with wastewater pathogens. Most studies show that risk of
infection from exposure to wastewater or sludge is minimal. There is evidence that
exposure carries a slight risk of viral infection, particularly in workers with the highest
exposure levels. Overall, researchers tend to show surprise at having encountered so
little disease among wastewater workers.

Besides examining the medical history of wastewater workers, past exposure to disease
organisms can be determined by measuring antibody levels.
Measurements of serum antibody levels have been used in many studies
During the past 10 years to see if workers have a history of prior infection with
pathogenic viruses, bacteria, and certain parasites and fungi. Higher antibody levels
frequently occur in inexperienced workers (<5yrs.) than experienced workers.

• Case history: North Side Sewage Treatment Works; Skokie, Illinois.

Study in which particulates from sewage and air samples collected at
the plant were inoculated in guinea pigs. In one experiment using

Undiluted sewage, Legionella pneumophila was identified in spleen cells 6-7 days
later. Infections were not detected in animals inoculated with aerosol samples.

• Case history: Cincinnati, Ohio; Chicago, Illinois; Memphis, Tennessee.

To determine if the prevalence and level of antibodies were higher in
wastewater-exposed people and whether the number of infections as
indicated by increases in antibody concentration were different
among the various study groups. Study showed that wastewater
workers are not at significantly greater risk of disease nor source of
viral infections to
To family members. In a few instances, levels of antibody to certain viruses
appeared related to level of exposure to wastewater aerosols. Bacterial aerosol
levels higher in sludge handling buildings than adjacent to aeration tanks at the
same plant.

HELMINTHS (worms, cysts, etc): The most common parasitic helminthes in the USA are
Ascaris lumbricoides, Trichuristrichura (whipworm), Necator americanus (hookworm),
and Taenia saginata (beef tapeworm). The potential sources of parasites in municipal
sludge are untreated wastes from slaughterhouses and meat and poultry plants. Ascaris
ova (eggs) are extremely resistant to treatment processes and are used as indicator
organisms of parasite contamination and the survival of parasites in sludge. The number
present in the human host is dependent upon the number of ova ingested, because the
worms do not reproduce in the body. Tapeworm infections can spread by livestock
grazing on soils containing sludge in which eggs are present; or man can ingest the eggs.
9. Do treatment processes reduce or kill disease-causing organisms?

The disease-causing organisms found in sewage are almost entirely of human origin and
are mostly of enteric forms; that is, organisms which infect the human intestinal tract,
although a few cause respiratory infections. The microorganismal content of raw sewage
reflects the type and number of infections experienced by the community served by the
sewage system; this will vary from community to community and country to country. It is
not necessary for people in the community to show disease symptoms; viruses, for
example, are shed in large quantities in feces of even healthy carriers.
The types and numbers of pathogens decrease drastically in the course of conventional
sewage treatment, so the health risks will vary throughout the process and will depend
upon the type of treatment.

The disease organisms which require a host in which to reproduce are not going to be
able to reproduce in the sewer system. This means that when these organisms are shed
into the water by the infected person, the number of organisms may decrease (die-off as
well as dilution) or remain constant during passage down the pipe to the treatment
plant, but will not increase. Also, the risk of disease, especially by the skin contact route,
may depend upon the concentration of disease organisms in the sewage. The closer to
the source, the higher the concentration since little dilution will have occurred. Also,
some organisms, including the viruses, may adsorb to sewer films or settled solids and
be of risk to sewer workers. The dilution factor for feces in household or community
sewage is in the range of 1000 to 10,000. (For example, a pathogen present in the feces
of 1-10% of the members of a community at a level of 108/g might occur in raw sewage
at levels of 105 - 107/1iter.)

Overall, total fecal coliform analyses probably do not provide an accurate

microbiological profile for the survival of pathogens in sludge.

In general, some pathogens such as Salmonella typhosa (salmonellosis) have a short

survival time in wastewater; M ycobacterium spp. (tuberculosis and others), Ascaris ova
(roundworms), and certain enteric viruses appear highly resistant to treatment
processes.
PRIMARY TREATMENT does not significantly reduce pathogens, although primary
sludges may contain large numbers of parasite eggs.

Most parasites present in raw sewage are found in primary sludge, including pathogenic
bacteria and viruses due to affinity with settleable particles. It is disputed whether
viruses are removed almost exclusively in primary sludge; there is too much variation
and uncertainty in the methodologies used to study viruses. Primary treatment tends to
remove 80 - 90% of Salmonella; 50% of Mycobacterium; and coliform removal varies
from 27 - 96%.

SECONDARY TREATMENT: As previously discussed, biological treatment may have a

destructive effect on the viruses; removals in activated sludge range from 50 - 90%.
Activated sludge has a low removal for eggs and cysts; removals range from 85 -99% for
pathogenic bacteria. Waste solids do contain surviving pathogens. Secondary sludge
may be expected to contain a major portion of the microbial population which was
removed from the raw sewage. In activated sludge, viruses are removed by adsorption
to flocs; however some sewage microflora are capable of virus inactivation. This may be
due to metabolic products released by sewage organisms or to toxic substances present
in wastewater. Some bacterial enzymes break down the viral protein coat of viruses
such as Coxsackie, Flavobacterium, Aerobacter; and Klebsiella bacteria can inactivate
poliovirus in activated sludge.

ANAEROBIC DIGESTION appears to reduce coliform populations considerably, but other

pathogens such as Mycobacterium and Ascaris ova can withstand prolonged digestion.
For viruses, inactivation rates ranged from 74.9%/day for Echovirus 11 to 90%/day for
poliovirus to 97%/ day for Coxsackie virus A-9. This appears to be due to bacterial
digestion of the virus’ protein coat. Although significant pathogen reductions can be
achieved by anaerobic digestion in laboratory studies, actual plant digesters appear less
efficient - this may be due to the continuous input of contaminated raw sludges along
with possible short-circuiting and incomplete mixing. After digestion for sludge
subsequently dried in lagoons; research from Ottawa, Canada, has shown that even
after eight months of lagoon-drying, sludge still contained detectable amounts of
viruses.
OXIDATION PONDS: Pathogens entering oxidation ponds may be removed by
flocculation, inactivated by sunlight, or inactivated by pond microflora, especially
protozoa, rotifers and nematodes. Sunlight is probably the significant factor due to
ultraviolet rays. The lethal effect of ultraviolet light is due to the absorption of UV by
viral proteins and nucleic acids (DNA or RNA) which leads to changes in the protein
structure and to breakage of the nucleic acids. (For example, for raw sewage exposed to
sunlight for 5.5 hours during a four-day period, poliovirus 1 was reduced to zero in the
upper 1 inch of sewage. At lower depths, the virus was more stable.) Ponds remove a
significant portion of indicator and pathogenic bacteria, but viruses are not completely
removed.

DISINFECTION, specifically chlorination, of effluents has yielded studies which lack

specific information on initial chlorine dosage, reaction temperature, pH, and the level
of organic or inorganic nitrogenous compounds present. This makes it difficult to
compare published results of chlorination studies. However, some microorganisms,
such as species of Mycobacterium, amoebic cysts, and certain enteric viruses (including
hepatitis A), are reported to be more chlorine-resistant than indicator coliform
organisms. For example, chlorinated secondary effluent has been found to contain 50
virsuses/1. However, without chlorination, 1-10% of Salmonella, Mycobacterium, and
some enteric viruses are probably surviving in the effluent after secondary treatment.

SANITARY LANDFILLS and LEACHATE: Diapers are a major source of enteric viruses in
sanitary landfills. Viruses may be adsorbed to solid waste components or the 1andfi11
may have some inactivating property (e.g., heavy metals) or high temperatures during
decomposition of waste (60C).
Whatever the reason, virus inactivation increases with increasing ages of landfill. As
a result, landfill leachate tends to have little or no viruses.

10. How can we find out whether wastewater workers are exposed
to diseases?

Organisms have been found in workers themselves using throat or rectal swab samples or
examination of feces. This kind of evidence confirms that infection has actually occurred.
VIRUSES: All viruses that infect the enteric tract are shed in the feces. Although large
numbers of viruses which infect the respiratory tract are swallowed, they tend to be
inactivated by stomach acid or by the bile salts encountered in the intestine. A number
of viruses are shed in the urine, such as mumps and measles, cytomegalovirus, and
congenital rubella.
Viruses may be shed by individuals who never develop disease (subclinical infection), or
during the last day or so of the incubation period, or form chronic carriers whose infection
persists long after evidence of the disease disappeared.

Enteric viruses do not grow in the external environment and appear generally to have a
limited life span in soil and water. Although enteroviruses have been infrequently
identified in sewage aerosols so far, they have been found in abundance in sewage.
Primary and trickling filter treatments have only a modest effect on virus levels in sewage;
while activated sludge can remove 90-98%, there is concern that some viruses may be
areosolized. The respirable particles may become trapped in the nasopharynx of exposed
persons, an appropriate site to initiate an infection.

Poliovirus was once the most feared of all viral diseases, but the impact of the Salk
and Sabin vaccines has been so effective that it has been virtually abolished in
Western countries. Poliovirus is spread by direct fecal contamination of hands or
contamination of water supplies by sewage.
Modern standards of hygiene and sanitation have restricted its spread; wild viral strains
are rarely found in human sewage, but the vaccine strains are common.

Other enteroviruses (Coxsackie virus and Echo virus) are common viruses causing a
variety of diseases such as upper respiratory tract infections, gastroenteritis, meningitis,
paralysis, pancreatitis, myocarditis, endocarditis, and hepatitis A. They enter through the
mouth and are present first in the throat and then in the feces for some days.

A study of stool samples of sewer workers in Rennes, France, found the protozoan
Entamoeba histolytica in 11% of sewer workers, but only 2% of non-sewer workers. In
the same study, 16.5% of the sewer workers had
Giardia Intestinalis (now called G. lamblia). Hamburg, Germany, sewer workers have
found to have increased infection rates with Entamoeba coli, Endolimex nana, and
Giardia lamblia. Antibodies to these organisms have been found in the blood of workers.
A study of workers at wastewater treatment plants in Cincinnati, Chicago, and Memphis
showed higher levels of antibodies to Norwalk agent, rotavirus, and echovirus 3 and 6
than in unexposed people. Further, the inexperienced workers showed even higher levels
than experienced workers.

Antibodies to adenovirus, influenza type A, and parainfluenza type A were studied in

wastewater workers in Bucharest. The more exposure they had to wastewater and
sludge, the higher their antibody levels to respiratory viruses. Wastewater workers in
Copenhagen have shown higher levels of antibodies to hepatitis A when compared to
nonsewage workers. Studies or workers at sludge or wastewater land application
projects indicated seroconversions (antibody levels) to enteroviruses, Cocsackie B,
echoviruses, and polioviruses for Ohio; Lubbock, Texas; Muskegon, Michigan; Sweden;
and Israeli kibbutzims. However, the results were not clinically significant except in
workers with high wastewater exposure who cleaned the irrigation nozzles. Workers in
Memphis had higher antibody levels to Salmonella than workers used as controls.
Workers at facilities in Philadelphia, Camden, Washington, D.C. and Beltsville were
involved in heat-drying of sludge or sludge composting have high antibody levels to
endotoxins released from the cell walls of Gram-negative rod-shaped bacteria. Workers
at sludge composting sites may have some risk from inhalation of spores of the fungus
aspergillus fumigatus. Some fungal species may cause hypersensitivity reactions or
produce mycotoxins (similar to endotoxins).

However, it is possible for exposed workers to have protozoa in their stools and yet not
have detectable antibody concentrations for that organism. For example, this was the
case for some Hamburg, Germany, and sewer workers infected with Entamoeba
histolytica. Researchers have recommended that serological (antibody) tests may not be
the best way to study parasitic infections.
Studies undertaken to test for disease exposure can include:

• Skin tests for tuberculosis and fungal infections

• Liver function tests for hepatitis
• White blood cell (leukocyte) counts
• Urinalysis for fibrinogen degradation product (FDP) concentration
• Air samples taken at treatment plants to show the presence of
wastewater organisms in the air at and near the facilities.

One example of the last kind of study was conducted at the John Egan Plant,
Schaumburg, and Illinois, prior to and after the initial operation of this new plant. The
study examined pathogenic bacteria, viruses, parasites in clinical specimens, viral
antibodies in serum, specimen trace metal levels, and the reported incidence of relevant
disease and symptoms. A household’s health survey was conducted for persons living
within 5 kilometers of the plant.
Air and wastewater were sampled for pathogens and metals. The levels of
microorganisms and metals in the neighboring residential areas were not
distinguishable from background levels. The nearby residents did report a higher
incidence of skin disease and several gastrointestinal symptoms after the plant became
operational, but antibody tests and attempted isolations of pathogenic organisms
showed virtually no clinical evidence of disease associated with wastewater aerosol. In
fact, some surveys have shown that people who live near wastewater treatment plants
show higher levels of some of the same diseases, the closer they live to the wastewater
treatment plant.

11. Do wastewater workers actually get sick from disease exposure at

Work?

Yes, occasionally they do. They need to take in an infectious doses by inhalation or
ingestion; few organisms can penetrate the skin. Many illnesses and infections are
subclinical and discovered by antibody levels or other tests, but actual diseases have
occurred. These can be verified by looking at shedding of the organisms in the feces.
LEPOSPIRA bacteria enter the body through cuts and abrasions of the skin or by contact
with the mucous membranes of the nose, mouth, or eyes. It has been considered an
occupational health risk of wastewater workers in the British Isles and Germany. This
has been especially true for sewer maintenance workers; the route of entry appears to
be direct contact of cuts and skin abrasions with urine infected rats. The incidence
among sewer workers declined from 8% (1933-1948) to 2% (1978-1983); this has been
attributed to modern pest control measures, the use of protective clothing, and the
presence of detergents in wastewater which rapidly destroy Leptospira. The Cincinnati-
Chicago-Memphis study (cited earlier) showed some antibodies present in wastewater
workers.

Since Leptospiral antibody levels fall rapidly after the infection is over, the detection of
the antibody depends upon how close the study is done to the time of infection. Failure
to detect Leptospiral infection in sewage workers may be due to lower background levels
of antibody, lower exposure to wastewater, or both. The recent studies in general suggest
that although some risk remains, Leptospirosis is no longer a major problem in sewage
workers.

Wastewater workers in Cincinnati, Ohio: Anchorage, Alaska; and Ontario, Canada; have
contracted hepatitis A. The Ontario workers worked in a primary purging station, grit
chambers, and maintenance on sewer cleaning machines. The Ohio workers included
construction workers at the wastewater treatment plant and a chemist. Researchers in
the Hamburg, Germany, and wastewater workers study recommended that amebiasis
and giardiasis be considered as occupational diseases for wastewater workers. Endotoxin
exposure at sludge-drying composting facilities has produced fever and chest-tightness
reactions in exposed workers.

Parasitic worms have not been studied yet in wastewater workers.

Overall, researchers have tended to conclude that the risk of viral diseases, based upon
antibody studies, appears low. However, many of the infections studied in wastewater
workers have involved sporadic epidemics which are more difficult to investigate.
Bacterial diseases appear to also show a low risk for wastewater treatment generally,
but heat-drying and composting of sludge appear to carry some risk of endotoxin
exposure and its effects. Workers at a wastewater treatment plant in Gothenburg,
Sweden, a heat-drying operation where sludge was converted to dust, experienced
episodes of chills, fever, and malaise. Also white blood cells moved into the eyes to fight
eye inflammation. All these are typical symptoms of endotoxin exposure.

Workers during their first years of employment, especially the first 5 years, may
experience increased rates of gastrointestinal or upper respiratory illnesses. This may be
because time is needed for their immunity to become established.

12. What about the risk of contracting heRatitis B or AIDS?

There have been few studies of these diseases; but, so far, studies of antibody
levels in wastewater workers have shown hepatitis B does not appear to be
effectively transmitted via exposure to wastewater itself.
However, in the 1983 annual Safety Survey conducted by the Water Pollution Control
Federation, one utility reported that a worker had received Workers’ Compensation for a
hepatitis B infection. During the 1990 hearings on OSHA’s proposed standard on blood
borne disease (due to become a final rule in 1991 or early 1992), a sewage worker from
new York City told of contracting hepatitis B from a needlestick while screening debris
from raw sewage in 1987.

The Center for Disease Control (CDC) allows Human Immunodeficiency Virus (HIV)
contaminated blood and body fluids to be carefully poured down a drain leading to a
sanitary sewer because they believe that wastewater workers are not at increased risk
of contracting bloodborne diseases. Wastewater temperature, pH shifts, chemicals, and
dilution itself are believed to quickly inactivate the HIV virus. From 1990 to 1993, several
studies have been published which suggest that this conclusion is probably correct. HIV
needs an intact outer envelope to be infectious; its outer membrane is susceptible to
disruption under conditions of unfavorable
osmotic pressure (such as the virus coming into contact with tap water or wastewater,
which are so different from human blood or body fluids). An experiment in which blood
from State IV AIDS patients was mixed with dechlorinated tap water indicated that the
osmotic balance was so severely affected that virally infected cells were no longer
detectable after 5 minutes. Once membrane rupture occurs, noninfectious HIV can still be
detected by using techniques to recover viral RNA or proviral DNA. The use of the
polymerase chain reaction (PCR) technique enables very tiny amounts of RNA or DNA to
be recovered from wastewater, amplified, and then detected. PCR techniques have
needed to amplify the virus a millionfold or more to be able to detect it (even at picogram
levels); this supports the conclusion that the wastewater concentration of HIV is
exceedingly low.

But does this indicate that infectious virus is present? The results of one such study
appear to indicate that, although the PCR method can detect the presence of the virus’s
RNA and related DNA, this does not necessarily indicate the presence of infectious viral
particles. While recoverable RNA can persist for a few hours, HIV appears to have lost
its infectivity within minutes. The presence of blood serum in water can only briefly
slow the inactivation of HIV. Further, it would also appear that wastewater components
inhibit the action of the viral enzymes reverse transcriptase and DNA polymerase, also
needed for viral infectivity.

It is important to note that HIV is quite different from the traditional waterborne viral
diseases discussed in this manual. These viruses can replicate in high numbers in the
gastrointestinal tract, enter and be stable in wastewater, and thus be transmitted to the
wastewater worker via the (usually) respiratory route of entry and (for a few types) via
breaks in the skin. However, the replicative cycle of HIV does not introduce it directly into
wastewater.

Thus, the research so far still appears to indicate that the wastewater worker is not at
increased risk of occupationally-related HIV.

13. Can a worker get a disease from an accidental exposure, such as

Sewage splashed into the mouth?
Yes, this is possible. A sewer worker in Hamburg, Germany, developed an amoebic liver
access due to an accident involving the swallowing of wastewater.

For organisms which cause infection by way of the digestive tract, some may remain
there and cause disease. But others must work their way to other parts of the body
to cause disease. So, the outcome of an infection may be determined by how
effectively the organisms are confined to the intestines, rather than by how rapidly
the body suppresses the infection entirely. The enteric bacteria cause intestinal
disease by associating with the inner surface if the intestines.

Some organisms (such as Vibrio cholerae which causes cholera) cause diarrhea by
producing and excreting toxins that stimulate the intestinal cavity. Others induce
diarrhea by entering, multiplying in, and destroying the epithelial cells which line the
intestine. Infectious Escherichia coli can behave by either of the preceding
mechanisms. Other microorganisms can penetrate through and around epithelial cells
and then travel by way of the lymphatics and the blood to other organs in the body
where they cause systematic disorders. In some of these cases, the bacteria colonize
(multiply on) the intestinal surface. To survive there, bacterial pathogens
must resist or bypass the body’s defenses. An important component of these defenses
is the intestine’s normal bacterial inhabitants.

The digestive system is able to defend itself using the low pH of the stomach and the
regular rhythmic movement of the muscular wall of the bowel. The bile acids are
particularly toxic to bacteria, but some pathogens are relatively resistant to bile acids
(such as E. coli), some bacteria colonize the upper small bowel where the concentrations
of bile acids are low.
Mucous works well to trap microorganisms in the respiratory tract, but in the bowel,
certain pathogens may colonize mucous and use it as a food source. White blood cells
(phagocytes) inhabit the intestinal lining and appear effective against pathogens. The
normal bacteria of the human intestine interfere with pathogenic microorganisms, but
this defense does not function well in humans whose digestive systems are disturbed
by
antimicrobial or other drugs or starvation or emotional stress. For example, Vibrio
cholerae can only colonize the small bowel if the normal microflora have been upset in
some way (such as antimicrobial drugs), or substances have been eaten that slow bowel
mobility, or in children before
their normal flora have been successfully established. But, if a high concentration of
pathogens has been taken into the body, an infection might occur even in people with
normal intestinal flora.

In addition to these defenses, there are some specific mechanisms such as secretory
antibodies (particularly IgA). There is evidence to suggest that the normal intestinal
microflora prevent the destruction of the IgA antibodies by a person’s own digestive
enzymes and therefore help the body to defend itself. However, disease organisms such
as Neisseria gonorrhoeae and Streptococcus mutans produce enzymes that specifically
digest IgA antibodies.

It is possible for infection and disease to follow the ingestion of fairly small numbers of
Salmonella; higher numbers may simply decrease the incubation period. For example,
healthy adults and children developed Salmonella gastroenteritis after eating chocolate
Easter eggs and rabbits contaminated with levels of S. eastbourne of <1-100
organisms/l00g. Infection and disease (dysentery) may follow ingestion of very small
numbers of Shigella; about 25% of volunteers became ill after ingesting 180 cells.
Approximately 30% of the volunteers were not susceptible to Shigella at all, although
their serum antibodies levels did not indicate a high level of preexisting antibody. Other
defense mechanisms, as yet unknown, appear to be at work.

Similar human volunteers studies have been done with viruses, but it is difficult to
determine what doses were used since the studies often did not involve counting the
number of viruses per dose. For example, a study using vaccine polioviruses showed
that infections resulted after ingesting 1- 20 tissue culture doses; others have reported
infections only after 103.5 or more doses were ingested by large numbers of subjects. It
is difficult to determine the pathogenic dose because a tissue culture dose of an
enterovirus may be equivalent to 10 to 1000 virus particles.
Human volunteer studies with cysts of Entamoeba cofi showed that an individual who
received a single cyst became infected; when the dosages increased, the proportion of
subjects infected increased. A study with

Giardia cysts required at least doses of 10 cysts; however, some persons given high
doses (106) did not develop an illness. Cyst doses were easier to count since the cyst
content of a dose can be verified directly by microscopic inspection of the dose. A 2-year
old child who ate dirt, which had been spread with sludge several days previously,
contracted enteritis from Salmonella typhi.

It would appear that, although a single infectious organism may be capable of causing
an infection, a single unit almost never does produce infection. Usually a substantial
probability of infection is associated only with substantial numbers of infectious
organisms. More work needs to be done in studying how infections begin due to
ingestion of small doses and to determine the human factors that determine whether
infection leads to disease.

14. As the disease risk really so low?

Although no significant increase in human disease appears to be attributable to aerosols

from wastewater treatment plants, sludge application, or spray irrigation sites, these
studies are considered inconclusive by those who believe the potential exists. The issue
of potential versus actual risk is complicated by several factors which prevent a definite
conclusion about the health hazards.

t There are many common diseases with similar symptoms and many of these are
not reported.
4 Enteric disease organisms are not unique to wastewater. Wastewater aerosols
are not the only transmission route or source.
+ These are variations in the types and densities of microorganisms; and these
reflect the diseases in the population served by the wastewater treatment plant.
 Workers may have developed immunity due to their routine exposure to low
aerosol levels of disease organisms.
Studies are difficult to conduct since the population size of the entire community is
large in comparison to the small numbers who actually live near the treatment plant.
Sensitivity of the monitoring methods for disease resistance is lacking, especially at
low levels of antibodies.
The dose-response relationship is unknown as to what minimum numbers of
disease organisms are needed to initiate infection (especially via inhalation) for
most pathogens.

Workers who are exposed occasionally may be more affected than those who stay in
the most exposed areas continuously. This may be of importance to workers who rarely
rotate to different exposure areas in the plant. For example, a worker who normally has
very little exposure to wastewater aerosols, upon being moved to another area, may be
more likely to develop an infection than a worker who typically works around an
aeration basin or dewatering equipment.

15. Do wastewater workers develop allergies, other than reactions

to endotoxins or mycotoxins?

Yes, there have been documented cases of allergic asthma caused by exposure to sewer
flies )a Depteran fly of the Psychodidae family). One worker experienced seasonal runny
nose, eye irritation, and severe wheezing, but controls his symptoms by avoiding heavy
sewer fly debris exposures such as floor sweepings, as well as using medication.

16. How can exposure to chemicals and diseases be reduced?

Administrative controls can be used for rotating personnel among the various
treatment plant operations. This would reduce inhalation of air- stripped chemicals
and aerosols, and may help development of immunity to diseases by keeping exposure
low, perhaps too low for a disease-causing dose to be inhaled.
Engineering controls involve the use of ventilation for processes located within building,
as well as splash guards where appropriate for dewatering equipment, and a variety of
design or operational features to reduce air- stripping and aerosols of disease potential.
Air sampling for chemicals and airborne levels of organisms such as Gram-negative rods
can be determined to see if controls are needed. Some of the controls as reported in the
technical literature are described below.

A. Enforce pre-treatment regulations to reduce air-strippable chemicals at the

source.

B Plant trees around the aeration basin to capture the droplets and particles.

c. Reduce the amount of air-stripping and aerosol formation by using finer bubbles for
aeration.

D Reduce air-stripping and aerosols by using diffused aeration rather than mechanical
aeration.

E. Some researchers have theorized that it should be possible theoretically to reduce

the size of the bubble for aeration so that eventually the resulting droplets and
particles would be too small to carry any microorganisms, but unfortunately this
does not appear to be a very practical solution.

F. Reduction of aeration rate, if possible. Certainly your process control strategy may not
allow this.

G Consider floating covers on the mixed liquor of the aeration basin. Some plants have
had success with:

4 Biodegradable oils
+ Collapsing foam - detergents
G Permanent foam - Polyurethane sheets
G Ping-pong balls - floating on the surface
H. Consider suppressing the droplets just above the surface by using
these
methods:

Single layer screen - 100-200 mesh

Multiple layer or knitted mesh screen Fiber
beds
Foam or granular bed
Flat plate or slats over the tank
Water spray to beat down the wastewater droplets
Rotating brush

I. Consider collecting the droplets by:

Sedimentation Multiple
cyclone Scrubber
Electrostatic precipitator Fabric
Filtration

J. Consider disinfecting the airborne particles by using:

4 Ultraviolet lights

K. Cover the primary clarifier weir area. Shield the weir area from wind.
Use submerged effluent collector (such as pipes with orifices) rather
than weirs.

L. Avoid handling screenings by hand to prevent needlestick injuries.

M. Label piping so that potable and nonpotable water are

clearly distinguished.

N. Processes to significantly reduce pathogens are treatment processes

such as aerobic and anaerobic digestion, air drying, low temperature
 composting, lime stabilization or other techniques giving equivalent pathogen
reduction. If sludge treated in one of these ways is applied to land: food crops
which could contact sludge cannot be grown for 18 months, animals whose
products are for human consumption cannot graze for 1 month, and public access is
restricted for at least 12 months.

Anaerobic digestion: Greater reductions of pathogens depend upon longer detention

times and higher temperatures: e.g., 24 hours at 35 C, virus kill
74.9 - 97.1%. Almost complete destruction of schistosome and hookworm ova possible,
but Ascaris ova survival is high. Parasitic protozoans tend to be reduced to
nondetectable levels. Greater reductions are accomplished in smaller-scale reactors
than in full-scale plants due to elimination of short- circuiting. If sludge is dewatered and
dried, Salmonella are reduced by 90% when the sludge is dried to 95% solids at room
temperature. Taeni (tapeworm) ova survive about 14 days in the absence of surface
moisture.

Lime stabilization: elevating the pH to 11.5 to 12.0 for 30 minutes cab reduce pathogenic
bacteria and poliovirus. Lime stabilized sludge at pH = 12 were reduced by a factor of 10
to 1000 times less than anaerobically digested sludge. After the pH is elevated, it later
drops and this subsequent drop in pH can result in regrowth. For example, fecal
streptococcus bacteria was able to regrow to its original density in 24 hours.

Q. Process to further reduce pathogens: These are sludge treatment methods such as
gamma or beta irradiation to an absorbed dose of 1 Mrad, pasteurization or other
methods of equivalent pathogen reduction. PSRP is required first to reduce volatile
solids. If PFRP is used, the restrictions applied to PSRP are no longer required.

Irradiation: lonizing radiation kills salmonella and coliforms. Aspergillus niger spores
and polio virus; the larger microorganisms are the more susceptible.

Worker exposure can also be reduced by the use and proper care of
protective clothing and equipment.
 Heavy duty rubber gloves and boots can be used to prevent skin
contact with wastewater and sludges. Especially cover any skin trauma
such as cuts and abrasions to prevent infection. Use protective clothing
and goggles to prevent contact with spray and splashes.

Remove contaminated clothing after completion of a job. Avoid

laundering work clothes at home. If they are cleaned at home, place
them in a bag and leave them bagged until they are actually to be
placed in the washing machine. Wash them separately from other
clothing with the hot water cycle. Consider using chlorine bleach if
appropriate for the fabric; if not, use a no chlorine.

■ Shower at work and change into clean clothes and shoes.

Wash hands with soap and water before eating or smoking and
whenever hands come in contact with wastewater and sludge. Care for
cuts and abrasions promptly.

17. Should a wastewater worker be immunized to reduce the risk

of infection?

The following are recommended by the U.S. Public Health Service and the
Centers for Disease Control. Currently no additional immunizations have
been recommended for wastewater workers.

The Centers for Disease Control has so far concluded that there have been
no work-related cases of hepatitis. A transmission among workers exposed
to sewage; principally because the data form the serologic (antibody)
studies on workers exposed to sewage were not controlled for other risk
factors. If prophylaxis is desired for hepatitis A, there are two approaches
available: immune globulin and vaccination. Two vaccines are currently
licensed in the United States for hepatitis A and both consist of inactivated
hepatitis A virus. HAVRIX (manufactured by SmithKline Beecham
Biologicals) and VAQTA (manufactured by Merck & Company, Inc.). For
adults (over the age of 18 years), HAVRIX is administered in 2 doses with
the second dose
given 6-12 months after the first. For adults (over the age of 17 years), VAQTA is
administered in 2 doses with the second dose given 6 months after the first.

18.Are there adverse health effects from chronic exposure to low levels
of hydrogen sulfide gas?

There appear to be 2 types of effects depending upon the level of exposure:

A. central nervous system effects, and

B. local irritation

Systemic effects are the result of action on the nervous system; for hydrogen sulfide this
generally means respiratory failure followed by asphyxiation.
The respiratory center is stimulated causing rapid breathing which rids the lungs of
excessive carbon dioxide and breathing stops. Mortality from hydrogen sulfide exposure
can be reduced by increased attention to cardiopulmonary resuscitation at the exposure
site and during transportation to the hospital. These effects may be accompanied by
short-term electrocardiographic changes, elevation of blood nonprotein nitrogen levels,
and the appearance in the urine of red blood cells and hyaline casts. Cardiac effects
have included both hypertension and hypotension, tachycardia (abnormally rapid
heartbeat of over 100 beats per minute) and bradycardia (very slow heartbeat of under
60 beats per minute).

Several mechanisms have been proposed as to why this happens: the most popular
theory says that the enzyme cytochrome oxidase, which is involved in the body’s use of
oxygen, is poisoned in a similar manner to cyanide poisoning. A different theory
suggests that hydrogen sulfide may cause an initial increase in nervous tissue activity
which brings about neuropsychological and other effects such as a slow heartbeat. It has
also been suggested that autooxidation of hydrogen sulfide in the tissues results in the
formation of hydrogen peroxide which is actually responsible for some of the toxic
effects of sulfide on the central nervous system.
 DISEASE WHO NEEDS IMMUNIZATION IMMUNIZATION

Hepatitis A Individuals with close personal immune globulin;

contact with persons with hepatitis hepatitis A vaccine
A; travelers; persons with chronic
liver disease; children living in
communities with high rates of
hepatitis A; children and young
adults in communities that have
intermediate rates of hepatitis A.
Hepatitis B Homosexual males and household Immune globulin;
and sexual contacts with carriers. hepatitis B vaccine
For direct exposure to blood of a
person known or suspected to be a
carrier. For occupational
transmission, as per USDOL.OSHA
CFR 1910.1030.
Influenza Adults 65 years or older Annual influenza
vaccine
Measles Adults born in 1957 or later, unless Combined measles,
they have evidence of vaccination mumps, rubella
on or after their first birthday, (MM )
documentation of physician
diagnosed disease, or laboratory
evidence of disease
Pneumococcal disease Adults 65 years or older Pneumococcal
polysaccharide
vaccine
Mumps Adults, especially males, who have Mumps vaccine
not been previously infected
Rubella Women of childbearing age, unless Rubella vaccine
proof of vaccination or lab
evidence of immunity is available
TD (Tetanus and Adults every 10 years after initial TD vaccine
Diphtheria Routine doses, after wounds unless
less than 5 years since last
dose
When taken into the body, some of the hydrogen sulfide dissociates to form the
hydrosulfide anion (HS-). Methemoglobin (an early stage of hemoglobin manufacture)
competes with cytochrome oxidase to react with and bind the toxic hydrosulfide anion.
When methemoglobin binds to hydrosulfide to form sulfmethemoglobin, this causes a
condition
called methemoglobinemia which actually helps provide protection against death from
acute sulfide poisoning. This enables the reactivation and protection of cytochrome
oxidase and aids the patient’s recovery by enhancing aerobic metabolism. The
treatment of hydrogen sulfide poisoning has involved giving a patient injections of
sodium nitrate to purposely cause methemoglobinemia: this was used successfully to
resuscitate one human severely poisoned by hydrogen sulfide.

The local irritant effects of hydrogen sulfide involve a direct action on the tissues and
local inflammation of the moist membranes of eyes and respiratory tract because of
hydrogen sulfide’s high solubility in water. This ability to dissolve rapidly in the mucous of
the nasal passages is what leads to an overloading of the olfactory nerve endings causing
their paralysis and thus the loss of the ability to detect this gas at higher concentrations.
The hydrogen sulfide gas dissolves in the moisture and dissociates to form an acid which
then irritates the conjunctival and respiratory mucosa. There are infrequent incidences of
this irritation being accompanied by pulmonary edema (fluid in the lungs). When inhaled,
the irritant action is more or less uniform throughout the respiratory tract, although the
deeper pulmonary structures suffer the greatest damage. Studies in animals suggest that
the macrophages in the alveoli of the lungs are impaired in their ability to combat
bacteria by the action of hydrogen sulfide; this may cause increased susceptibility to
infections such as pneumonia.

The eye irritation and inflammation of the conjunctival and corneal tissues is called “gas
eye.” It is often accompanied by pain, watery eyes, and sensitivity to light
(“photophobia”). In severe form, it may progress to acute keratoconjunctivitis with
associated blistering of the corneal epithelium.
Rupture of these blisters may, in some cases be followed by corneal ulceration which
could heal with scar formation and permanent impairment of vision.
The dry surfaces of the skin are seldom affected by gaseous hydrogen sulfide. The most
important route of absorption is through the lungs; proper respiratory protection
covering only the face and head will permit work to be carried on in atmospheres
containing concentrations which would be immediately fatal to the unprotected worker.
It does not appear that skin absorption of the gas is a major route of entry; industrial
experience
suggests that cutaneous absorption must be many times less efficient than pulmonary
absorption. Hydrogen sulfide has been noticed to retard the healing of minor skin
wounds.

Overall, if the victim survives, there appear to be no long-term adverse effects form
acute exposure (aside from the possible eye damage mentioned above). It appears that
if the exposure is not immediately lethal and adequate support is provided, there is a
reasonable expectation for complete recovery. The site of exposure is an important
factor; most exposures necessitating hospitalization occur in enclosed or confined
spaces; exposures in the open air to hydrogen sulfide has produced problems of lesser
magnitude. Substantial decreases in worker mortality have been attributed to improved
first-aid training, increased awareness of the dangers of hydrogen sulfide, conducting
continuous personal and environmental monitoring, and the effective use of personal
protective equipment.

Hydrogen sulfide has not so far been linked with carcinogenesis, mutagenesis, or
teratogenesis. One study concluded that there was a “weak teratogenic effect” in rats
following low-level exposures to a combination of hydrogen sulfide and carbon disulfide,
but no strong evidence supporting teratogenic effects from hydrogen sulfide exposure
only.

What happens with chronic exposure to hydrogen sulfide gas? Hydrogen sulfide is
principally eliminated by the body through the kidneys in the form of sulfate or sulfide.
There is some elimination of the gas through the lungs although there appear to be no
reliable estimates on the quantitative importance if this method of excretion. Hydrogen
sulfide generated by intestinal microflora in flatulence is, at least in part, systematically
absorbed and detoxified.
The characteristic signs and symptoms of systematic hydrogen sulfide poisoning occur
only when free, unoxidized gas is present in the circulating blood steam. To cause
systematic intoxication, the gas must be absorbed at a rate faster than it can be
eliminated or detoxified. Because detoxification proceeds at a very rapid rate, H2S can
be considered as a noncumulative poison; this is why it tends not to be considered as
having chronic

The effects of hydrogen sulfide gas on the body may be divided into three categories:
acute, subacute, and chronic. “Acute” has been used to describe episodes of systematic
poisoning that have occurred rapidly and in which the central nervous system effects
( such as respiratory paralysis) have predominated. “Subacute” has been used to describe
cases in which the local irritant effects have predominated. As for “chronic” there is no
unanimity of opinion that this condition actually exists; it has been suggested that it is
probably a series of low-grade “acute” episodes. As with any toxic substance, the effects
of exposure depend so much upon both the duration and the intensity of exposure.
Because the body has an inherently large capacity for detoxifying sulfide, the toxicity of
the gas is more closely related to concentration than to length of exposure. It should be
understood that in any case of exposure to this gas, both local and systematic injury may
result.

Can adverse health effects be caused by low levels of hydrogen sulfide gas (e.g., under
5 parts per million)? There is some evidence that hydrogen sulfide alone at low
concentrations or in combination with other chemical substances (e.g., hydrocarbons
or carbon disulfide) has caused nervous system, cardiovascular, and gastrointestinal
disorders such as diarrhea, headache, fatigue, irritability, insomnia, and effects of the
eyes. The American Congress of Governmental Industrial Hygienists (ACGIH) lowered
the threshold limit value (TLV) of hydrogen sulfide from 20 parts per million (ppm) to
10 ppm with short-term exposure limits at 15 ppm because, at low concentrations, eye
effects are predominant with conjunctivitis the most common effect, while keratitis
frequently occurs.
Some eye effects have been reported as low as 4 or 5 ppm. Low concentrations
have been observed to interfere with the healing of small wounds.
Are there adverse health effects from chronic exposure to low levels of hydrogen sulfide gas (under 5ppm)?
Conclusive evidence of adverse health effects from reported, long-term exposure to hydrogen sulfide at
low concentrations does not appear to have been found. Although persistent effects on humans after long-
term exposure have not been conclusively demonstrated, numerous studies suggest that there may be a
series of low- grade subacute effects.

Cases of eye irritation similar to those more recently attributed to chronic exposure were reported in the
18th century by the Italian physician Ramazzini, considered the father of occupational medicine. His
treatise on occupational health reports on the physical condition of sewer cleaners who experienced eye
irritations.

One historical case of what may have been chronic hydrogen sulfide poisoning has been reported in a
workman who was exposed to hydrogen sulfide for 2 years in the early 1900’s at a sulfur-black
establishment. In 1905 he experienced lack of muscular coordination, pains, paresthesias (sensations of
numbness, prickling, or tingling), muscular atrophy, and a narrowing of the visual field. By 1906, he was
totally blind with pain and persistent paresthesia; he died of bronchpneumonia in 1910.

Microscopic examination of sections of the spinal cord revealed no inflammation, but extensive
degeneration.

One study in rats showed abnormal changes in the cerebral cortex of the brain from chronic exposure to
7 ppm (10 milligrams per cubic meter) for 12 hours a day for 3 months.

Chronic exposure to low concentrations may result in conjunctivitis (gas eye) or occasionally pulmonary
edema. Habituation to exposure does not appear to exist; on the contrary, hyper susceptibility may
result.

Hazardous Substances & Dangerous Goods Procedure

Introduction
This procedure outlines the requirements for the management of hazardous substances and dangerous goods in the
workplace to minimise affects to health and safety from exposure and reduce the impact on the environment. The
procedure summarises labelling, material safety data sheets (MSDSs), risk assessment requirements, storage and
disposal.

Scope
This procedure relates to all workplaces and work processes using hazardous substances that any worker,
contractor or visitor may undertake.

Definitions
Carcinogenic - capable of causing cancer.
Class label - the label illustrating the class allocated to a substance under the ADG Code1.
Dangerous Goods – a hazardous substance also defined by the Dangerous Goods Act, (as amended), to be
dangerous. They are classified on the basis of immediate physical or chemical effects that may impact on people,
property or the environment – explosive, flammable, corrosive, chemically reactive, highly combustible, acutely
toxic, radioactive or infectious.
Dangerous goods class - the class allocated to a substance under the ADG Code1.
Designated Hazardous Substance is a hazardous substance that is:
1. listed on National Occupational Health and Safety Commission (NOHSC) list of Designated Hazardous
Substances above its lowest cut-off concentration or
2. That is determined to be a hazardous substance by the manufacturer or importer of the substance on the
basis of NOHSC's Approved Criteria for Classifying Hazardous Substances.
Hazard is a source of, or situation that has the potential to, harm a person, the environment or damage property.
Hazardous Substance – is a substance that contains ingredients that may be harmful to health in the medium or long
term.
Label means a set of information on a container which identifies the substance in the container, identifies whether the
substance is hazardous and provides basic information about the safe use and handling of the substance.
Material Safety Data Sheet (MSDS) – information sheets that provide technical information in relation to substances.
These sheets are obtained directly from the manufacturer. Be aware of the possible differences between the
manufacturer’s and generic MSDS’s.
Risk is the probability (likelihood) of harm or damage occurring from exposure to a hazard, and the likely
consequences of that harm or damage.

Roles and Responsibilities

Managers/Supervisors are responsible for:
 keeping the register and MSDSs up to date
 identifying hazardous substances and dangerous goods and completing risk assessments
 providing appropriate information to workers in relation to hazardous substances and dangerous goods
 Implementing appropriate risk control measures in consultation with workers in keeping with the Hierarchy of
Control.
  conducting investigations of incidents involving hazardous substances or dangerous goods
 reporting any notifiable incidents involving hazardous substances to Work Safe Victoria

Workers are responsible for:

 using control measures and any other actions designed to protect health and safety
 Participating in the development of appropriate risk control measures for hazardous substances and
dangerous goods in keeping with the Hierarchy of Control.
 Reporting any incident involving a hazardous substances or a dangerous good.

Material Safety Data Sheets (MSDS’s)

MSDS’s are required for all chemicals that are deemed hazardous by the NOHSC. MSDS’s must be obtained for all
chemicals in use or stored.
The MSDS’s must:
 be readily available to personnel using the substances with information on chemicals in a form that is easily
understood by the user
 identify if the substance is a designated hazardous substance
 Meet the needs of those employees with language or literacy difficulties.

The manufacturer’s MSDS must be updated every five years and is obtained from the supplier. Contracts for the
supply of hazardous substances to the Company must include provision for the supplier to supply the appropriate
MSDS and must notify any changes in formulation.
Hazardous Substance Register
Hazardous substances used at all workplaces must be identified listed on a register (use WHSFOR- 7A). Non-hazardous
chemicals should also be included on manifests. A collection of MSDS shall be readily available to workers and
constitutes part of the Register. This register should also state dangerous goods status/class of any of these substances
as well as maximum quantities and location. The register should be current at all times and should be updated when
new substances are introduced to the company.
The register should also include notation of simple and obvious risk assessments which have been conducted on
hazardous substances. No further report or record is required.
Manifest and site plan of the premises
The main purpose of the manifest is to provide the emergency services authority with information about the quantity,
type and location of dangerous goods stored and handled on premises to enable them to respond appropriately if
called to an emergency. Workers should be aware of the location and purpose of the manifest.
The manifest should be located within ready access of emergency personnel; however it should not be in an area
which may become inaccessible due to the associated risk. The hazardous substance register may also be used as the
emergency manifest.
More information is available from Guidance Note for Emergency Services Manifests
Labelling
All containers containing any substance must be labelled appropriately. MSDS’s will provide the information required
for labelling.
All containers should be clearly labelled including any risks or significant hazards posed by the substance. Other details
should include; directions for use, first aid and emergency requirements, expiry date, manufacturer’s details.
Identification information must be noted including, product name, chemical name, UN number and ingredients
and formulation details (where relevant).
Placarding
Legislative requirements for placarding of premises are dependent on volumes and packaging groups of hazardous
substances. The following can be recommended as a minimum requirement for the organisation to minimise risk to
emergency services, contractors and employees;
 Placarding on any entrance roads to the premises
 Placarding at the entrance to the buildings
 Placarding on entrance doors to storage facilities
 Placards for class 3,6 and 8
 where there is storage greater than 25Lt of hazardous substance (with the exception of class 6.1 packaging
group 1. where it is 10Lt)
Placarding involves the use of hazardous substance diamonds indicating class and Hazchem placards for entrances.
More information is available from the Guidance Note for Placarding Stores for Dangerous Goods and Specified
Hazardous Substances .This should be referred to determine if placarding is required under legislation. Placarding
should also be dependent on risk assessment for the areas.
Storage
All hazardous substances are kept in secured storage facilities. The doors are kept locked except when there is an
employee present who has been assigned the responsibility of accessing this area.
General Requirements for the storage of all Dangerous Goods
The area where dangerous goods are stored should be:
 Well ventilated and well lit.
 Separated from ignition sources.
 Secured from the public.
 Protected from temperature fluctuations and direct sunlight.
Secondary containment (e.g. spill trays) should be considered for dangerous liquid goods stored outside of a chemical
storage cabinet.
Dedicated areas should be provided for measuring out chemicals.

Segregation of Chemicals
In general, each class of dangerous goods should be segregated by a physical barrier. More detailed information is
available from the MSDS.
The risks involved in the interaction of incompatible substances can include;
 uncontrolled release of heat
 emission of noxious fumes
 Explosion.
It is important that Hazardous Substance Risk Assessment form is completed prior to the mixing of chemicals

Shelf Storage
Where chemicals are kept on shelves or racks the following is recommended;
 Shelving must be compatible with the goods stored
 the shelves should be constructed of chemically resistant materials
 shelving systems must be designed to hold the maximum holding capacity of the chemical containers;
 Incompatible chemicals should not be stored together on shelves.
 solid chemicals should preferably be stored on upper shelves above liquid chemicals;
 Secondary containment (bonding) is essential for large containers. As a priority all dangerous goods of this
size should be bonded.
 Shelves should have raised edges to reduce the likelihood of dislodging.
 the most dangerous chemicals should be stored at easily accessible heights (e.g. 1.5 m from the floor)
 Chemicals should not be stored in direct sunlight.
Storage in Refrigerators
Where refrigeration is required for hazardous substances, there must be a dedicated refrigerator which is or has been
made intrinsically safe. Substances for human consumption must not be stored in the same refrigerator.
Storage in Cabinets
Where chemicals are stored in cabinets it must be ensured that;
 The cabinet is marked with the appropriate hazardous class diamonds
 They are constructed of chemically resistant material
 Flammable liquid storage cupboards must be self-closing with two points of contact
 Incompatible substances are not stored together.

Disposal
MSDS’s should be viewed to determine the most appropriate means of disposal. All substances no longer required are
to be removed from the site by a licensed operator for disposal, as per Environment Protection Authority (EPA)
guidelines.

Purchase of hazardous substances

Prior to purchasing any hazardous substance, consideration should be given to the possibility of using a safer
substance. The following procedure should be followed prior to any purchase:

1. Request an MSDS on identified substance. Review health hazard information.

2. Conduct a risk assessment taking into account the potential hazards and exposures.
3. Make a determination about whether there are adequate controls in place, whether more are required, or
whether there is a more suitable substance with less risk?
Ensure on receipt of substance all measures are in place to control identified risks.

Emergency response
Risk assessments will have taken spills and their consequences into account and have documented procedures. The
location of the spill should be taken into consideration when assessing potential environmental or safety concerns.
Where required, spill kits should be available for use in the event of a spill and documented on the risk assessment. All
personal protective equipment should be available and used in the event of spills.
In the event of a spill/leakage the following procedures should occur:
1. Ensure there is no danger to anyone in the area.
2. Attempt to contain the spill using appropriate PPE.
3. Absorb any liquids with sand/kitty litter etc.
4. Inform the senior manager of the spill
 5. Dispose of waste as per disposal instructions on MSDS
6. Inform any regulatory bodies as required i.e. EPA / Work Safe Vic
Spill Kits
Spill kits should be available for use where assessed as required. The contents of the spill kit should be relevant to the
area and the potential spill; this may include such things as;
 heavy duty plastic bags or plastic drums (with a lid) to contain hazardous material prior to disposal (this can
be used to store all items)
 a couple of bags of kitty litter, saw dust or sand to absorb spilt liquids
 brooms, dustpans and a square mouth shovel to sweep up the absorbent material
 absorbent pillows or booms to contain larger liquid spills and prevent spills entering drains
 appropriate personal protective clothing (such as chemical resistant gloves, safety glasses)
Ensure that the spill kit is clearly labelled and located in an easily accessible position for all Workers. Spill kits should be
restocked following use and the contents should be checked on a monthly basis.

Risk Assessment
For any process using hazardous substances a risk assessment should be performed and recorded.
For a substance to be used, the hazardous substance risk assessment form must be completed in consultation with
relevant workers or contractors.
The process shall compromise the following;
1. Perform a simple and obvious risk assessment on all substances to be used.
2. All processes to be undertaken must have a risk assessment undertaken, taking into consideration all
hazardous substances, unless a prior risk assessment has been completed. Utilize Hazard Management/ Risk
assessment form implement all controls prior to the process commencing.
3. All risk assessments are to be included in the hazardous substance registry.
4. Generic risk assessments can be undertaken for processes which are performed on a regular basis and are
utilizing the same processes. These are to be stored in a section of the hazardous substance registry in a
designated area.
Risk assessments need to be reviewed in the event of: change of process, plant or substance, new information on
hazards, inadequate exposure control being identified and new or improved controls becoming reasonably practicable.
All risk assessments must be reviewed every 5 years at a minimum.

Simple and obvious assessments

Simple and obvious risk assessments are performed by consulting the MSDS. This is used to provide information on the
handling and use of the particular substance and also to identify whether it is classed as a hazardous substance. If the
inspection of the work shows that any risk can be, or is already, controlled in accordance with the MSDS (or the
equivalent information about precautions for use and safe handling), then the assessment is complete and no further
assessment is needed. This can be then noted in the register.

Detailed assessments
For some work a more detailed assessment may be required. These situations include those where:
(a) There is uncertainty about the degree of risk;
(b) There is a significant risk to health, for example, exposure to a hazardous substance may be high and/or the nature
of the health hazard is serious; or
(c) More complex chemical processes and/or exposures are involved.
A more detailed assessment might involve obtaining additional information about health hazards, a thorough
evaluation of the work to determine exposures (including monitoring where appropriate), and examination or testing
of existing control measures.
Note: If atmospheric monitoring is required, it needs to be carried out by an appropriately qualified person (or
competent person depending on the complexity of the task) and the data must be recorded/kept (30 years)

References
 Work Health and Safety Act
 National Model Regulations for the Control of Workplace Hazardous Substances
 Approved Code of Practice for the Control of Workplace Hazardous Substances National Code of Practice for
the Control of Scheduled Carcinogenic Substances NOHSC: 2014(1995)
 National Model Regulations for the Control of Scheduled Carcinogenic Substances NOHSC: 1011(1995)
 National Guidance Note for the Labelling of Workplace Substances (NOHSC: 3013(1991))
 Guidance Note for Placarding Stores for Dangerous Goods and Specified Hazardous Substances
(NOHSC:3009(1990))
 Guidance Note for Emergency Services Manifests (NOHSC:3010(1990))
 Australian Code for the Transport of Dangerous Goods by Road or Rail
 Malaria Control Procedure

 Malaria is a killer disease common in many tropical countries including the Solomon
Islands. Malaria attacks can cause severe sickness including high fever and body ache
and can lead to death if not treated or managed properly.
 Effects of malaria results in Site absenteeism, less food , less money earning and
increase disability (economy).

What causes malaria?

Malaria is caused by a parasite (germ or small worm) called Plasmodium. The
parasite (germ or small worm) infects and destroys the person’s blood. There are
four species of Plasmodium malaria parasites that infects humans but only two are
the most common ones in the Solomon Islands (SI). They are Plasmodium falciparum
(PF) and Plasmodium vivax (PV). Plasmodium vivax can cause relapse or stay in the
body and become active again. Plasmodium falciparum can cause severe malaria
resulting in death.

How to prevent malaria?

 Prevention of malaria includes methods to control mosquitoes breeding sites,
stop mosquitoes from biting people, kill adult mosquitoes and clear the
malaria parasite in the body before it causes malaria. Important methods for
preventing and controlling malaria are.
 Environmental clean-up – eliminate or destroy all mosquito breeding places
and conduct general clean-up of bushes and tall grasses where they live.
 Insecticide-treated mosquito nets and house screening – prevent adult
mosquito biting in the house.
 Indoor residual spraying – killing of adult mosquitoes in the house.
 Presumptive treatment – killing of malaria parasite in the blood before they
cause malaria.
 Mosquito repellents – mosquito coils and local remedies.
 • Individual protection – wearing long sleeve and trousers.
 • Early diagnosis, timely and adequate treatment of all malaria cases.
2.2 Treatment
 If your blood test result is positive with malaria, then you will be given treatment.
 Only a nurse or doctor will prescribe (give) medicine to any patient with malaria.
 Patients must complete their medicine as advised by the nurse or doctor.
 Do not stop taking your medicine, even if you feel better before completing
treatment.
 Do not share your medicine with anyone.
 Always eat healthy food before, during and after taking your malaria treatment.

COVID-19 Management Plan & System

COVID-19 and social distancing have changed the anatomy of construction sites nationwide. Where
foreman and laborers once took the little things for granted, like personal space, hygiene practices, or
even a slight case of the sniffles, they must now pay extra attention to even the most routine of jobsite
activities. COVID-19 has changed the way we work, making easy tasks vastly more complicated.

It’s not all bad news though; the Coronavirus might present frustrating and uncharted territory, but
construction companies that choose to proactively arm themselves with the right software solutions have
a powerful way of fighting back.

How the Workplace Has Changed

COVID-19 is a rapidly-evolving situation. While only a few solid facts are known about its transmission,
spread, and overall course, scientists and researchers are learning more and more each day. A short list of
workplace best practices based on OSHA COVID-19 guidelines is the result of that ever-increasing
knowledge base.

Multiple organizations, including the Center for Disease Control (CDC) and World Health Organization
(WHO), recommend the following safety precautions in the workplace:

Keep a minimum of 6 feet in between yourself and others

Wash your hands frequently
Wear a face mask in public
Avoid touching your face
Use hand sanitizer when hand washing resources are unavailable
Report any change in your health status to your supervisor immediately
Construction worker wearing mark - safety management software
While these are general health and safety at work guidelines meant to prevent or slow the spread of the
disease, each one of them applies to the construction industry just as much. That presents its own set of
unique challenges, however.

If coronavirus does rear its ugly head on your job site, safety management software gives your company
the agility to deal with reporting and compliance issues quickly and efficiently, allowing you to focus on
keeping your employees safe and preventing an outbreak from completely shutting down your operations.

We have provided a checklist for employees and workers working on the site:-

Employee Covid-19 Screening Checklist

First Name Last Name

Email Phone number

What is your current temperature? °F °С

Are you experiencing any of the following symptoms?

Cough Yes No

Fever Yes No

Shortness of breath Yes No

Persistent pain or pressure in the chest Yes No

Loss of smell or taste Yes No

Chills Yes No

Muscle aches Yes No

Sore throat Yes No

Headache Yes No
Any other symptoms?

Have you had close contact in the last 14 days with an

individual diagnosed with COVID-19? Yes No

Have you traveled internationally or

domestically in the last 14 days? Yes No
If you reply YES to any of the questions above, or start feeling sick during your
shift, inform your supervisor immediately.

Signature

Date

If you reply YES to any of the questions above, or start feeling sick during your
shift, inform your supervisor immediately.

Signature
Date