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 Presentation on

“Safety in Construction”
Prakash Nirwan
28th June’12 , Hotel New Marrion, Bhubaneshwar

SAFE KONNECT 2012

“Moving ahead in Industrial Safety”

Confederation of Indian Industry

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“Safety in Construction”  2734
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European Engineering Standards English, and Ger man

Presentation on theme: "“Safety in

Construction”"— Presentation transcript:

1 “Safety in Construction”
Presentation on
“Safety in
Construction” Prakash
Nirwan
Write With Confidence
28th June’12 , Hotel New Marrion, Bhubaneshwar
SAFE KONNECT 2012
“Moving ahead in Industrial Safety”
Confederation of Indian Industry

2 Contents of the Presentation Pack

Check your gramm Background & Importance of Safety in
and pu insta Gra Construction Project details for 6 Mtpa at
Tata Steel, KPO
Tata Steel’s initiatives in Construction Safety

3 Importance of Construction Projects

ar, The Construction industry is an important indicator of
spelling, the development:
nctuatio Creates investment opportunities across various related
n ntly sectors
Contributes in Economy Growth (Approx. 10 % in
Developing Countries' GNP)
Major Employment Generator
At the same time it is also associated with
proportionately high number of job-related accidents
due to:
Labour intensive nature
Continuously changing working environments
Involvement of several di"erent agencies
Custom of employing migrant farm labour from lower-
wage economies for short term

4 Importance of Construction Projects

Thus addressing Construction Safety Performance and the safety of the
workers in the construction industries can have a great impact on:
Reducing injuries
Cost associated with safety
Project delays
5 Challenges of Construction Industry in India
Socio-Economic Problems
Competent Manpower
Cultural Gaps
Environmental Impact assessment
Unorganised Sector
Construction Activities
Labour Camps
Safety Awareness
Social Hazards at Site
Training Infrastructure
Source: Godrej : Safety Control in Construction Industry

Study Result of 1996 in UK shows….

The construction industry had:
15 victims per 1,00,000 workers as compared to
4 per 1,00,000 workers in all other industries combined
The frequency of disabling injuries in construction industry
5300 per 1,00,000 as compared to
3100 per 1,00,000 in all other industries
“The records of the last 45 years confirm the trend that the Construction
Industry has VERY high fatalites and injury rates.”
Source: European Journal of Scientific Research

Accident Statistics during Construction

Helander (1991) in examined 739 construction deaths that occurred in the UK based
on the following categories used for classifying fatal accidents :
Source: European Journal of Scientific Research

Key Factors in Accident Prevention

Based on Model Survey analysis, the Six Most Important factors in
Accident Prevention are:
Maintaining Safe Work Conditions
Establishing Safety Training
Safety Education to support good safety habits amongst workers and supervisors #1 Free DevOps
E"ective Control of the main contractors on site
Maintaining Close Supervision of all work f SF
Assigning Safety Responsibility to all levels of management and
workers Source: European Journal of Scientific Research

Key findings of study on Accident Prevention

Study focusing on Middle Level Management found that:
Management attitudes have more influence on Safety than the foreman or peer
groups
Workers work more Safely for a supervisor who respects his men and their
contribution
Better co-ordination improves Safety
Work on piece rate basis rather than a fixed hourly basis increase the
probability of accidents
Source: European Journal of Scientific Research

Go 10x Faster than Chan

Contents of the Presentation Pack Sets. Sign in with SF &
Background & Importance of Safety in Construction Tr Copado Essentials for
Project details for 6 Mtpa at Tata Steel, KPO Fr
Tata Steel’s initiatives in Construction Safety

MOU Signing Between Tata Steel and Govt. of Odisha on

17th November’04

Location in Kalinganagar Industrial Complex

NINL
MESCO
Jindal Stainless
Rohit F/A
VISA
Jakhapura
Rly Station
Copado
Tata Steel
Plot-1
Plot-2
BRPL

Major Production Units

KPO: Major Facilities &
Capacity Major Production
Units Capacity/Size
Raw material handling system
19 mtpa raw materials
Coke oven by-product plant: 4 Batteries
2.8 mtpa Gross
Coke Sinter plant
496 sqm
Pellet plant
4.25 mtpa
Blast Furnace
2 x 4300 cu
m
Lime Calcining Plant Learn More
3 x 600 tpd
Steel Melt Shop
6 mtpa slab
Hot Strip Mill
5.5 mtpa
Cold Rolling Mill
2.2 mtpa
Captive Power Plants:
By-product Gas Based
Coal based
3 x 67.5 MW
3 x 150 MW

Contents of the Presentation Pack

Background & Importance of Safety in Construction
Project details for 6 Mtpa at Tata Steel, KPO
Tata Steel’s initiatives in Construction Safety

Challenges in Green Field Project

Lack of Industry Culture (Safety Knowledge & commitment)
High proportion of unskilled & temporary workmen
Transient nature of contract workers during construction activities (Frequent Work
Team rotations)
Exposure to weather conditions (Extreme Hot, humid & stormy)
Indiscipline (Personal Behaviour)
Societal issues (Intoxication habits)

Safety Management System at Tata Steel

Apex Safety Committee
Divisional Implementation Committee : KPO
Area Implementation Committees (20)
Sectional Implementation Committees 50)
Training & Communication
Safety Standard
Incident Analysis
OHS
Process Safety
Contractor Mgmt.
Construction and Contractor Management
Training and Communication
PSRM
Rules and
Procedure
Positive Isolation
Observation & Audit
Road and Rail Logistic
OHS & Environment
Road & Rail Safety

Safety Organization Focus Areas

(DuPont Methodology to achieve World Class Standards)
Line Management Accountability & Responsibility
Construction & Contractor Safety Management
Process Safety Risk Management
Rules, Procedures & Performance Standards
Positive Isolation
Safety Observation and Audit
Incident Investigation &
Analysis Road & Rail Safety
Occupational Health & Environment
Training & Communication
Consequence Management & Motivation

World Steel Survey-Critical areas(based on Fatal) FY11

80% of these causes are applicable in construction phase
Total 120 Nos.

Means to address Hazard Material Falling / Material Handling

Action Plan: Material Handling & Working at Height
Activity /
Process
Hazards associated
Means to address
Hazard Measures
Fool Proof
Fail Safe
Fail Soft
Material Falling / Material Handling
Crush, impact, hit injury
Monitoring & control of overloading of trucks, dumpers etc.
Toe guards to sca"olding (for arresting material falling from height)
Practice of chain lashing with necessary fixtures like bracket, D-Shackles, turn
buckles as per Transportation Safety Standard
Working at Height
Fall from height, Injury due to falling objects
Adherence to Barrication Standard at excavated pits
Working platforms, life line, Use of double lan-yard harness, fall arrestor and
safety net
Compliance to Sca"olding Standard
Issue of Height Pass based on medical test
Isolating work place under working at height

Chain lashing with fixtures during transportation

Fail Soft: Working Platform & Lifeline

Working Platform and Lifeline
23/05/12
23/05/12

Use of Safety Nets during Structure Erection

Working at Height : Safe Soft Methodology

Use of Full Body Harness and Double Lanyards

Compliance Monitoring of Sca"olding Safety

Visual Display of Sca"olding Checking Status

Safe Access for working at height

Material Handling using Tower Cranes

Action Plan: Heavy Vehicles / Mobile Equipment’s movement

Activity / Process
Hazards associated
Means to address
Hazards Measures
Fool Proof
Fail Safe
Fail Soft
Heavy Vehicles / Mobile equipment's movement
Hit, dash, collision, run-over
Helperless Driving
Use of reflective stickers to heavy vehicles
Separate walk ways for pedestrian within each site
Flag man to guide heavy mobile vehicles
Access control thru physical barriers
Mandatory use of high visibility jackets
Rest rooms near workplace at site
Side & Rear Run under protection guards to heavy
vehicles Weekly monitoring of illumination level
Heavy vehicle fitness checking thru weekly audits

Pedestrian Walkways within sites

Run-over Protection Guards & Flagman

Use of High visibility jackets & other PPEs

Heavy Vehicle & Mobile Equipment Safety

Use of Reflective Stickers
Heavy Vehicle Audits

Means to address Hazard Moving Machinery & Stored Energy

Action Plan: Electrical & Moving Machinery Hazards
Activity / Process
Hazards associated
Means to address
Hazard Measures
Fool Proof
Fail Safe
Fail Soft
Electrical
Electrocution, Injury due to Electric Flash
Compliance to Temporary Electrical Wiring standard
Implementation of Positive Isolation
Earthing of tools, appliances and equipments
Goal Post below HT lines
Fire extinguishers and rubber mat at Electrical DB rooms
Moving Machinery & Stored Energy
Hit, crush, entrapment
Guarding of chains and rotating parts
Maintaining safe distance between moving material and rigger
Presence of Flag Man for earth moving equipments and heavy vehicles

Fool Proof : Goal Post below HT line

crossing Placement of Rubber Mat in front

of
Electrical Panels

Means to address Hazards

Action Plan: Improve Road Safety
Activity / Process
Hazards associated
Means to address
Hazards Measures
Fool Proof
Fail Safe
Fail Soft
Road Safety
Crush, hit, dash, collision, run-over
Road Safety Awareness Campaigns
Audio-visual alarms & signage
Deputing Road Traffic Volunteers / Flag Men
Restricted movement of two wheelers inside site
One way traffic inside site
Access control system (Safety Induction Pass
System) Training on defencing driving to drivers
Audits for intoxication checking for drivers
Speed Monitoring camera inside site

Road Safety Initiatives

Deployment of Flagman
Speed barriers at junction points

Display of Road Safety Signage & Directional Board (One Way

Traffic) Means to address Hazard

Action Plan: Safety during Excavation
Activity / Process
Hazards associated
Means to address
Hazard Measures
Fool Proof
Fail Safe
Fail Soft
Excavation
Fall from height, entrapment
Hard barrication to excavated pits and use of net
Periodic Excavation Inspection Report for monitoring Slope Ratio, Shoring,
Shielding, Barricades, Water Removal and Over burden at edge
Monitoring stability of earth moving equipments
Use of rebar caps for improved visibility & to protect sharp
edge Verification of excavation safety standard thru
Checklist

Hard barrication & benching at Excavated Pits

Use of Rebar Caps

Means to address Hazard

Action Plan: Fire Management & Confined Space
Activity / Process
Hazards associated
Means to address
Hazard Measures
Fool Proof
Fail Safe
Fail Soft
Fire
Management
Heat / Burn
injury Hot work
checklist
Fire Fighting Training
Audits for Fire Safety
Fire Tenders and Extinguishers
Confined Space
Gassing, Poisoning, Asphyxiation
Compliance to Confined Space Standard
System of gas detection and impact assessment
Work Permit for Confined Space

Fire Fighting Training & Demonstration

Spatter Protection while Hot Work at Height

Display of Emergency Contact Numbers and Communication

23/05/12
23/05/12

Employee Recognition

Safety Communication in Local Language

Safety Communication in Local Language

Let’s join hands to make SAFETY a way of Life….!!

Thank You
Journey Continues…..!

Back-up Slides

Risk Review Methodology

Process Safety Development Phases in Major Projects
Project Phase
Risk Review Phase Name
Goals of Risk Review
Risk Review Methodology
1&2
Conceptual
Choosing inherently safer option, ensure overall feasibility, estimate impact on
neighbours
- Consequence modelling - What-If (no guidewords) - Selected checklist for
judging inherent safety
3
Preliminary Design
Identify & resolve most expensive design alternatives, including layout of plant,
facility siting concerns, environmental protection issues and major tie-ins
- What-if (no guidewords) - HAZOP / FMEA of selected scenarios - Layers of
Protection Analysis (LOPA) of selected scenarios
4
Detailed Design
Identification of potential accident scenarios, preliminary focused on normal
mode of operation Begin risk assessment for scenarios with large residual
risk
- HAZOP / FMEA of equipment nodes, focusing on normal mode of
operation - What-if of lower consequence & lower complexity systems LOPA of
1-5% of the scenarios: Determine Safety Integrity Level (SIL)
5
Final Design
Update results of previous Risk Review for new details, identify potential
accident scenarios for nodes not previously reviewed, primarily focused on
normal mode of operation. Resolve most previous recommendations Complete risk
assessment for scenarios with large residual risk
- Complete HAZOP, FMEA or what-if for nodes started in previous Risk
Review - Perform HAZOP, FMEA, What-if for nodes not covered in previous Risk
Review (due to previous missing info) - Begin Human Factors and Facility
Siting checklist - Perform general Utility Failure checklist - LOPA of 1-5% of
the scenarios: determine SIL, as necessary

Risk Review Methodology

Process Safety Development Phases in Major Projects
Project Phase
Risk Review Phase Name
Goals of Risk Review
Risk Review Methodology
6
Commissioning
Conduct full hazard / risk review of operating procedures to control risk of
errors during start-up, shutdown & other non-routine modes of operation
Close out previous Risk Review issues (from earlier phases of project) and
complete human factors and facility siting checklist This Risk Review creates
"Initial PHA" of the process
- HAZOP (2 guideword or 8 guideword) or What-if (no guideword) of
operating procedures (choose method based on hazard & complexity of each
task) - Complete HAZOP, FMEA or What-if for nodes started in previous risk
reviews - Perform HAZOP, FMEA, What-if for nodes not covered in previous
risk reviews (due to previously missing info) - LOPA of 1-5% of the
scenarios; determine SIL, as necessary - Complete Human Factor and
Facility Siting checklist
7
Post-Start-up
Conducted after 3-6 months after start-up similar to the future Revalidation,
but with the goal of compensating for weaknesses in MOC process at the
initial start-up of the new unit / process
- Audit of MOCs (and P&IDs and SOPS) since "Initial PHA" to ensure noting has
been missed by MOC - HAZOP or What-if of missed or poorly reviewed changes
- Update PHA for the entire set of changes (looking at a whole picture for
the e"ect of all changes) - Close any pending recommendations (if
possible)

DO IT Define critical behaviours to improve,

Observe target behaviours during a baseline phase to set specific goals for
achievement,
Intervene to change the target behaviours in the desired direction, and
Test the impact of the intervention by continuing to observe the target
behaviors. Consider the power of rewarding safety feedback to increase safe
work practices. Praising people for safe work practices:
Increases the probability that these work practices will be performed safely in
the future,
Builds a more open and positive safety culture

Managers Role to Improve Safety Culture

Safety rules are consistently and fairly enforced.
Suitable personal protective equipment (e.g., safety glasses, harnesses) is readily
available to employees.
Work schedules don’t compromise employees’ safety (e.g., excessive overtime,
unrealistic production pressure).
Management spends sufficient time on the floor interacting with employees.
This increases employee input for safety.
This shows employees that “management cares”.
Employees are actively involved in managing safety e"orts.
Safety management systems (e.g., training, discipline) are in place and e"ective.

Backup for Challenges in Construction slide

Properties :
Dynamic in Nature
Frequent work team rotations,
Exposure to changing weather conditions,
High proportions of unskilled and temporary workers.
The safety record of the construction industry is very bad w.r.t. other
industries due to
Complexity of the work or system,
Risk nature of works,
Management commitment and way of working,
Safety knowledge and commitment at individual level
Personal behaviour

Targets : Lead Indicators Proactive Safety Measure Tools Target

Timelines
Imparting Pre-employment & job specific training
100%
Implemented & Ongoing
Compliance to Work Permit System
Safety Communications: Mass Meeting Job specific hazards communication
thru PEP talk
- Monthly per site - Daily at the start of the
shift Visual SOPs in local language
2 per AIC
Monthly
Promoting culture for Near Miss incidence reporting
As & When happens
On-going
Job Cycle
Checks 1 per
officer
Safety Observation visits by TSL
employees 3 per officer
Contractor Safety Audits for identifying severity 4 & 5 observations and corrections
by: - Contractor Supervisors - AIC / SIC - Safety Professionals
- Daily - Twice a week - Thrice a
week Incident Investigation
As & When required
Pre Start up Safety Review for all critical
equipments FY14

Stamp Charged Coke Ovens

Schedule & Process Flow Sheet
Lime Plant
600 tpd x 2 nos: 0.4 mtpa
600 tpd x 3 nos: 0.6
mtpa Blast Furnace
4300 m3 x 1 no: 3.2 mtpa
4300 m3 x 2 nos: 6.4
mtpa Sinter Plant
496 m2 x 1 no : 5.75
mtpa Pellet Plant : 5.0
mtpa
Stamp Charged Coke Ovens
1.5 mtpa
3.0 mtpa
Converter
310 t x 2 nos: 3.1 mtpa
310 t x 3 nos : 6.2
mtpa Slab Caster
2 strand x 1 nos: 3.00 mtpa
2 strand x 2 nos: 6.00
mtpa Hot Strip Mill
2000 X 25 mm: 3.5 mtpa
2000 x 25 mm : 5.5
mtpa Unit
Phase – 1 (Comm : 2013)
Phase – 2 (Comm :
2015) Cold Rolling Mill
1870 X 0.3 mm: 2.2 mtpa

Line Management Accountability & Responsibility:

‘The only proven way of achieving Excellence in Safety Management’
Felt Leadership: Developing culture to accept Safety as personal responsibility
for themselves and those reporting to them
Accountability of line managers for the Safety Performance in their area of
responsibility
Safety information sharing during daily safety meetings, Mass meetings, AIC &
SIC meetings
Visible in area of work through frequent safety site visits for observations
(safety contacts) and Contractor Safety Audits

Construction & Contractor Safety Management

Providing training on Contractor Safety Audits to contractor’s Supervisors. Support
and hand-holding by TSL Project Managers & Safety Professionals
Daily Audits by site supervisors of Contractors & Consultants, Weekly Site Audits by
AIC / SIC members & twice a week audits by TSL safety professionals for
identification and immediate correction of severity 4 & 5 observations
Managing Contractors’ Safety performance in accordance to the same safety
standards and procedures as with our own employees
Clarity on Safety expectations wrt Tata Steel Standards & Procedures & procedures
to all Contractor owners thru Contract Terms

Process Safety Risk Management

Formation of PSRM Safety Subcommittee team & Training on PSRM to
bridge knowledge gap
Plant and Equipment from Technological Leaders having in-built safety
features (Examples: HAZOP approvals for all designs prior to manufacturing &
supply, Covers for all cast house runners, in-built lockable positive isolation
features in all electrical panels)
Incorporation of specific Safety features in design of plant & equipment based
on past learning (Examples: automatic drill bar changer for all tap holes in
Blast Furnace cast house, enclosed type goggle valves for gas lines for
elimination of gas exposure & positive isolation using hydraulic locking for
cast house machines) Ensuring adequacy checks of safety features at design
stage using PSRM. Quantity Risk Analysis in High Hazard Operations viz.
Gas holder, BF Bleeder etc.
 Procedures & Performance Standards
Deployment of TSL Safety Standards with focus on phase-wise activities
involved Safe Work Procedures for all the jobs & activities
Safe Operating Procedures in local language for day specific work, hazards
associated and mitigation measures
Job Cycle Checks by TSL employees to bridge gap in deployment of SWP
Shift-wise / Daily / Weekly / Monthly verification of compliance of ‘physical
conditions’ of critical Standards (Excavation, Gas Cutting & welding sets, material
handling Checks on
Task-based Risk Assessments for the high hazard / more critical tasks

Positive Isolation
My Life is My Life:
Positive Isolation Safety Subcommittee is working on following :
Energy Source Identification (Establish and approve procedure for Isolation points,
Method of isolation & The locking points)
Accreditation / Authorization for Isolating Persons
Formulation of Isolation Procedure for the Complex Isolation and Energy Source
Identification document
Deployment of equipment isolation using Personal Locks & System Locks thru
contractors is at early stages
Implementation of Methods of Isolation (i.e. Control Stop, Individual, Group
& isolation for working alone)

Safety Observation & Audit Process

Working on Safety Management System that includes two types of audits:
Behavioral Audits - to assess people and their conduct (Focuses on identifying,
disclosing and eliminating deviations resulting from improper, inappropriate and/or
unsafe behavior and conduct)
Managerial Audits - to assess the management system in terms of its
appropriateness and compliance (Assess levels of efficiency of the Process Risk
and safety management system)
E"ective use of 6-Step Safety Observation technique with focus on behavior
change thru Safety Contacts (identification of risks and mitigation
measures)
Rewards for Positive behavior & Consequence for repetitive negative behavior

Incident Investigation
Proactive implementation of learning from incidences at Jsr / other sites by
parallel deployment of key relevant recommendations
Addressing root causes thru Engineering Solutions / safeguards in Design
Stage Reporting & timely investigation of all incidents (tendency to hide &
difficulty due to skewed ratio of workmen to supervisors)
Promoting timely reporting of Near Misses by reward & recognition (for
contract employees)
Class room training on Incident Investigation for new recruits, project
managers of contractors

Road & Rail Safety

Road Safety - Major area of concern during Construction
Phase Physical:
Uneven approach, narrow & loose soil (non-compact) roads
Major excavation work and land filling activities : Heavy movement of earth
moving equipments
Outsourcing of dumpers by major contractors to multiple sub-contractors
Non-uniform illumination at construction sites
Incomplete periphery fencing / boundary
wall Pre-employment training facilities inside
site Human:
Deployment of non-educated drivers and
helpers Overtime working by drivers
Intoxication habits of local people
Delay in implementation of Gate Pass System

Rail & Road Safety

Actions taken and In-process / Proposed:
Heavy vehicle audits by CFT as per checklist
Detailed mapping of roads for material movement
Implementation of One way traffic & display of sign
boards Deployment of Road Safety commandos on
junctions Road Safety awareness Campaigns and
posters
Site-wise assigned parking place for heavy vehicles
Focus on constructing roads at site on priority before
monsoon Separate route for entry and exit of light &
heavy vehicles Restricted / No entry for two & three
wheelers inside plant Monitoring of driving habits through
electronic technology
Driving permits to be revoked before violations become collisions
Defensive driver training for issuing permit to drive at site
Proactive implementation of learning on Rail Safety from Jamshedpur

Occupational Health and Environment

Actions taken and In-process / Proposed:
Provision of Rest rooms and drinking water at each site
Installation of First aid Boxes, 1 First Aid Centre and 3 First Aid
outposts Procurement of Critical Care Ambulance
Creating pool of trained and certified First Aiders
Recruitment of Doctors and paramedical sta" in process
Maximize Solid Waste Utilization
Green Belt Development
Labour Colony – Health & Hygiene
Issues Recycling of bio-waste

Training & Communication

Leadership training with a focus on the behavioral aspects of safety for all
external recruits
Pre-employment Safety training / induction by external agency (NTTF) to all
categories of workers and re-training every six months
Contractor Safety Audit training to Contractor’s Senior Management to Site
Supervisor level and weekly monitoring of audit compliance
Monthly Safety Newsletter in Local language to connect with
family Plan to conduct:
Theme based safety awareness training on monthly basis thru visual SOPs /
Models, Do’s & Don’t in Safety Excellence Center (Infrastructure & facilities
creation under progress)
Contractor Orientation training for Sub-contractors
 7 Consequence Management & Motivation:
0
“Motivation”: The most important task and frequently the most difficult:
‘Walk the Talk’ and demonstration of passion for Safety at all levels
Constant communication on ‘Importance of Safe behavior’
Involving maximum possible employees in Safety initiatives
Timely addressing Safety concerns raised by employees
Acknowledging and appreciating safe act / behavior
Internal competition by recognizing Safe workplace
Consequence Management : Safety is the precondition of employment

7
Fool Proof / Fail Safe Approach
1
Created by: OS0059 Date:
8/13/2010 Doc. Classification:
Public

7
Fool proof: Following or executing such a plan that will eliminate the root
2
cause. So that even a fool will not be able to commit mistakes. This can be
done by providing mechanization or automation
Fail Safe: Planning in such a way that even if the situation arises, the e"ect
will be zero for e.g. a person may fall from height in case he stumbles, but will
be safe if he wears safety belt
Fail Soft: Planning is done in such a way that even if situation arises, the e"ect
can be minimized for e.g. A person may fall while driving two wheeler, but will
be hurt less if he is wearing helmet

7
Commonly used fool proof
3
3 pin plug
All Electrical/Electronics connectors.
Commonly used Fail Safe

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