BMW Industries Ltd., Gamharia Incident: Serious injury and fatality during handling of coil.

Date of Incident: 03/07/2018

Time: 05.10 PM
Location: Dispatch area, BMWIL Gamharia
Department: Service center
Section: Dispatch
Name : Mr. Raj Kaivart
Age : 24yrs
Designation : Contract employee
Experience : 6 yrs
Injury : Fatality of Mr. Raj Kaivart 
What Happened?
IP (sling man) along with other two of his colleagues
was engaged in loading of slit coils on to the trailer.
As part of his job, he was supposed to engage C hook
of the crane and guide the crane operator (sitting up
in crane cabin) to lift and move it to packing stand. The
crane operator lifted the coil from the coil cage and
started moving the cross travel. During the activity, the
hook with slit coil started to swing. IP seeing the swing
started to move back but was trapped by the trailer
parked behind him. The coil hit IP on the upper chest.
IP complained of uneasiness.
He was immediately taken to Tata Main Hospital
emergency ward and admitted at 18:01. He was later
referred to HDU. At around 8 pm, he succumbed to his
injuries.
Material handling
 Value Chain of Steel Business

Flat ProductsFlat Products Long Products

Sinter Merchant Mill
Fines Plant
LD1 New Bar Mill

CUSTOMER
Iron Ore Wire Rod Mill
Pellet
Plant Hot Strip Mill
Fluxes LD2

A-F Blast Hot

Metal Cold Rolling Mill
Furnaces
Coal Coke
Plant LD3 TSCR
Raw Materials Coke Sinter & Iron
Steel Making

3
coil Sheet packets TMT Coil TMT straight length

billets Slit coils Tubes

Cause of LTI
2012 – 2017 WSA Group Company FY’2016 – 2018 TATA STEEL (I) FY19 H1 - TATA STEEL (I)
Moving machinery 2061 Slip / Trip /Fall 66
Falling object 1421 slip/trip/fall 9
Product handling / storage 1400 on site road incidents 31
Fall from height 1219 manual task 29 Mannual task 7
Slip, trip, fall * 1181
Manual tasks and tools * 869 moing machinary 20 3
Other mobile equipment 651 falling object
On-site road / vehicle 583 falling object 15
Overhead crane 580 product handling 12 electric flash 2
Product loading 563
Hot metal 477 hot metal 8 2
Electrical 288 Hot substance
structure failure 7
Structural failure 286
Fire 220 explosion 6 Moving machinary 2
Off-site road / vehicle 214 hot substance 6
Forklift 210 On site Road vehicle 2
Hot substances * 179 electrical 4
Explosion 154
Rail 154 Fall from Height 4 product handeling 2
Object in the eye * 153 product loading 2
Gassing and asphyxiation 151 Hot metal 1
Exposure to chemicals * 56 fire 1
Cause wise LTIs
• Moving Machinery, Slip/trip/fall ,falling object , Product Handling & manual Task is the main
cause of LTI as per WSA report
• ~82% of injuries cause due to – Slip/trip/fall, Onsite Road Incidents, Manual Task, Moving
machinery, Falling object & Product handling for TSL (I).
 Introduction
 Manual handling is a common activity in most workplaces

 It includes lifting, lowering, pulling, pushing, carrying, moving,

holding or restraining an object

 Injuries and musculoskeletal disorders affect the back, neck,

shoulder, arms & hands

 It can be prevented through a systemic approach of identification,

assessment and control of risks associated with manual handling.
 People
• Operator
• Flag man
• Crew member

Handling
Rigging Equipment Equipment
• Rope Sling • Crane
• Chain • Fork lift
• D shackles • Hoist & Lifts
• Pulley blocks • Conveyors
• Chain pulley • Tower
blocks, etc…. cranes, etc….
Planning for hoisting and rigging.

 All activities of hoisting and rigging work have to be planned by a competent person.
 The load to be lifted should be known or reasonably estimated Magnitude and the final position of the load should be
known. The type of lifting device may vary depending on this.
 Position of crane shall be decided.
 Ground condition at crane position and crane movement area should be assessed.
 All nearby structures, electrical installations, utilities, trees etc. shall be identified, which will affect lifting and
movement of crane boom and lifted load.
 Depending on the arrangement of slinging, strength of every component of sling needs to be assessed.
 The load carrying capacity of lifting equipment or components of slings shall never be exceeded during lifting of load.
 For normal application, only one lifting equipment of adequate capacity shall be deployed.
 Sometimes, because of requirement of symmetry during lifting, or inadequacy of one equipment to lift the load, more
than one equipment is deployed for lifting. These lifts shall require special consideration of stability of load and
equipment at all phases of erection.
  After erection, the lifted structure or load shall be secured in position against all types of incedental forces including
wind. The load can be secured by erecction bolts, guy ropes, welding with other structures. This is to be planned along
with the planning for erection.
 Erection scheme shall be prepared by a competent person of the Contractor and approval shall be taken from the
representatives of Consultant and Executing Department.
7.2 General precautions for wire ropes, slings & rigging equipment.
• All rigging equipment should carry their unique identification number.
• No chain, rope or lifting gear shall be used unless –
 it is of good construction, adequate strength, suitable quality and free from any defects.
 it has been tested and examined once in a year for general use and once in six months for hot metal lifting use by a competent person and
issued a certificate.
 Rigging equipment for material handling shall be visually inspected prior to use on each shift. Defective rigging equipment shall be
removed from service.
 Only steel chains and slings shall be used for securing / supporting heavy loads (>= 70 kg) . Use of Manila ropes, Fibre ropes in rigging
activities is strictly prohibited for heavy loads.
 Rigging equipment shall not be loaded in excess of its recommended safe working load.
 Rigging and lifting equipment should be clearly marked with its safe working load and identification number.
 In case of multi-sling, the safe working loads at different angles of the leg shall not be exceeded. The upper ends of sling legs shall be
connected by means of a shackle ring or link of adequate strength.
 Rigging equipment, when not in use, shall be removed from the immediate work area so as not to present a hazard to other workforce.
 Slings shall not be shortened with knots or bolts or other makeshift devices.
 Every sling used for raising or lowering on lifting appliance shall be secured attached to the appliance and the method of attachment shall
not be a method likely to result in damage to any part of the sling or to any lifting gear supporting it.
 Precautions shall be taken through the use of suitable packing or otherwise to prevent the edges of the load from coming into contact with
the sling, rope or chain where this would cause danger.
 Hands and fingers shall not be placed between the sling and its load while the sling is being tightened around the load.
 Shock loading is prohibited.
 A sling shall not be pulled from under a load when the load is resting on the sling.
7.8 Chain pulley block (Ref. IS 3832 : 2005 - Hand operated Chain Pulley Block)
7.8.1 General requirement :
 The Chain Blocks should have safety Latch both in the Top & the Bottom hook
 Chain blocks of proper lifting capacity supported by Test Certificate should be used for lifting known loads.
 Chain block must be checked, and tested periodically. It should be lubricated before every use.
 No cannibalizing should be done on chain block.
 Chain blocks should be tested for slip by suspending safe load.
 It should operate freely and the chain should not come out of pulleys.
 The anchorage should be strong and rigid.
 They should be checked for cracks, excessive wearing, elongation, etc. Hooks opened out should not be used.
 No chain block / puller which has been tampered, be used unless it is thoroughly checked and tested by competent
person.
 Chain block / puller must be checked if stored for longer time, by subjecting to shock load, to observe slipping of load,
jamming of links etc.
 Use wire rope / sling for tying in (do not use Manila or Fibre Rope for tying purposes)
 Rigging equipment for material handling

• Shackles and hooks

– Manufacturers’ identification
– Never weld on hooks or shackles
– Working safety latch on hooks
Recommended Not Recommended Recommended

Screw Pin Anchor Round Pin Anchor Bolt Type Anchor

Shackle Shackle Shackle
 Never replace a
shackle pin with a bolt.

The load will bend

the bolt.
Avoid eccentric Proper chocking of
loads. shackles.

Bad Good
Bad Good
Check wear Check cracks, bending
and twisting

Check wear and

straightness

Pin always seated

Check opening width

 LOAD
Hooks are designed to
apply the load at the
bottom of the saddle.
 Check for Wear and
Deformation

Check for Signs of “Opening

Cracks and Up”
15% 10º
Twisting
Check that
Hook is Not
Twisted

Check for Wear and Cracks

Thanks