HSEmanual

Larsen & Toubro Limited
E & C Division
Safety Health & Environment Manual

for
Construction Site
LARSEN & TOUBRO LIMITED
E & C DIVISION
SAFETY, HEALTH AND ENVIRONMENT

MANUAL FOR CONSTRUCTION SITE
E & C Division SHE Manual
Contents
Part I: SHE - Administration

• Foreword
1. Introduction
2. SHE Policy
3. SHE organisation and Management
3.1. Management Commitment
3.1.1. Site commitment
3.2. SHE Organisation
3.2.1. Safety Control - Organisation Chart
3.2.2. Site Safety Organisation Chart
3.2.3. Duties and Responsibilities
3.2.3.1. Management
3.2.3.2. Safety Control Department
3.2.3.3. Resident Construction Manager
3.2.3.4. Site Engineer
3.2.3.5. Site Safety Officer
3.2.4. Returns
3.2.4.1. Site Opening / Closing Report
3.2.4.2. Monthly Reports
3.2.4.2.1. Monthly statistics report
3.2.5. Positive Reporting
3.2.5.1. Format
3.2.6. Daily Log – Book
3.2.6.1. Format
3.2.7. Safety Promotion and Recognition
3.2.7.1 Display Board of Safety Performance
3.2.7.2 Recognition
3.3. Statutory Requirements
3.4. Pre qualification for Selection and Performance of Contractors –
for L & T work.
Contents 1
3.4.1. Basic Requirements for Contractors

3.4.2. Rules governing contractor’s work
3.4.3. Safety in Contractor’s work
3.5. Safety Committee
3.6. Construction Safety Plan
3.7. Accident reporting and Investigation
3.8. SHE Audits
3.9. SHE Training
3.9.1. Tool Box Talks
3.9.2. Training at Site
3.10. Permit to work System
3.11. Safety of L&T Site Visitors
Part II: SHE - Implementation
4. Concept of Accident Prevention

5. Site Planning
5.1. Site layout
5.2. Construction details
5.3. In-built safety measures
5.4. Housekeeping
5.5. Safety at stores
6. Civil Work:
6.1 Blasting
6.2 Excavation
6.3 Piling
6.4 Working at heights
6.4.1 Ramps and Runs
6.4.2 Ladders
6.4.3 Scaffoldings
6.5 Demolition
6.6 Carpentry Workshop
6.7 Grinding Operation
Contents 2
7. Mechanical Works
7.1 Manual Handling
7.1.1 Winch
7.1.2 Reeving
7.1.3 Rigging Procedure and Precautions
7.1.4 Test Certificates
7.1.5 Operators & Banksman
7.1.6 Safe working load for men and women.
7.2 Crane Safety
7.3 Erection of Structures
7.4 Use, Care and Maintenance of Slings
7.4.1 Synthetic Ropes / Slings
7.4.2 Wire Ropes
7.4.3 Lifting Gears – Hooks, Shackles etc
7.5 Hoists
7.6 Other mobile machinery and their movement at the site
8. Critical Jobs:
8.1 Work over water
8.2 Confined Space
9 Welding and Gas Cutting
10 Health and Hygiene
10.1 Work Environment
10.1.1 Noise and Vibration
10.1.2 Lighting
10.1.3 Ventilation ( Heat Stress )
10.2 Personal Protective Equipment
Contents 3
11 Occupational Health Center and First Aid

12 Electrical Safety
13 Non Destructive Testing
13.1 Radiography
14 Abrasive blasting and spray painting
15 Hand tools and power tools
16. Handling of chemicals / hazardous substances
16.1. Handling and Storage of Chemicals
16.2. Material Safety Data Sheet ( MSDS )
17. Fire prevention
18. Onsite emergency preparedness plan
Part III: Commissioning of plant
Part IV: Environment protection

Environment Management (Construction)
Contents 4
FOREWORD
On behalf of Safety Control Department I am pleased to issue this

(SHE) Safety, Health and Environment manual to E&C division. This
manual will serve as a ready reference for methods and procedures to
be followed in Safety, Health & Environment by those who are
engaged in construction activity.
This four-section manual contains information based on the most

current knowledge and practices with the SHE (Safety Health &
environment) much of this information based on practice and research
and will remain relevant during the next decade. However changes are
bound to occur that will require Site managers to find innovative
solutions to SHE problems on the job.
The need for a SHE manual for those engaged in or concerned with
construction activity was recognized during the activities of Business
Specific initiatives for safety Assurance by the senior management.
I appreciate the assistance given by D.Venugopal our consultant, all

team members of safety assurance team and my colleagues in the
preparation of the text of the manual.
I hope, By following safe methods and procedures in construction let

us all in L & T E & C division make Safety - A way of life.
J.B.Desai
Dy.General Manager
Safety Control. E & C Div.
1. Introduction
1.1.1 This Safety, Health and Environment Management Manual has

been developed for Projects under construction in E&C Division
to ensure compliance of the Safety, Health & Environment
requirements during project construction.
1.1.2 This Safety, Health and Environment Management Manual

includes the procedures, responsibilities and safe practices
required to be followed at project site by all personnel involved
in the project, including crews and representatives of
Contractors.
1.1.3 This Safety, Health and Environment Management Manual shall

be followed while carrying out activities at project site and this
manual supersedes any other document on these subjects.
Introduction 1
Engineering & Construction Division
CORPORATE POLICY
1. To Engineer and Execute projects with consistent quality, cost and delivery in line with
the requirements of our customers, and to exceed or meet their expectations, whilst
enhancing our shareholder value.
2. To set and review quality objectives for Continual Improvement of our products and services,
whilst implementing the globally recognised management systems for Quality, Safety,
Environment and Information Technology, and integrating these systems with our business
partners and customers.
3. To design / operate and maintain safe and environmentally friendly plants which meet all
applicable statutory and regulatory requirements.
4. To advance / ensure the use of better and cleaner technology to minimise adverse
environmental impacts.
5. To continually reduce the risk of pollution through setting environmental objectives in

our design / operation and maintenance processes, based on the feedback.
6. To deploy Information Technology for increasing the efficiencies of our business

processes, while ensuring its security by protecting information as valuable assets and
ensure availability, integrity and confidentiality of all information.
7. To comply with all applicable occupational Health & Safety legislation and continually
improve safe working practices through setting health and safety objectives and
ensure good health, safety and security of all our people, our biggest asset.
8. To encourage enthusiasm, innovation and empowerment whilst developing inspiring

leaders to make working at L&T a rich experience and create new global benchmarks in
whatever we do.
9. To promote a culture of mutual trust, caring and sharing achievements, with our people,
our society, our stakeholders and our customers for the growth and benefit of our
Nation.
10. As an undisputed leader in the Indian context, we continue to make things that make
India proud, and shall strive to be amongst the globally outstanding companies, which
the World is proud of.
__________________________
Date: 3rd May, 2000 K. VENKATARAMANAN
(Member of the Board & Sr. VP)
3. SHE organisation and Management
In order to implement the policy of the management given under

chapter-2 SHE policy, a committed organisation is required. After
careful consideration the management has made Safety
organisations at different levels with each person’s commitment
well defined. These are given in this chapter.
3.1. Management Commitment
The E&C Division of L&T, is committed to continuous

improvement in creating and maintaining:
- A safe and healthy Environment at all its work places and
project sites
- A Zero accident record;
- A risk free operation;
- An improved business performance; and
- A responsible image within the marketplace.
SHE Organisation & Management 1

E & C Division
SAFETY COMMITMENT
Pursuant to the L&T Safety Policy Statement, we L&T employees at this

site shall comply with the L&T Safety Management System by the
following actions.
! Work with competent and adequately resourced contractors to
carry out work and ensure their co-ordination and co-operation.
! Ensure that contractors have information about risk on-sites and
they provide details of how they intend to safely carry out high risk
operations.
! Ensure that workers on site will be given adequate training and
comply with the site safety rules.
! Monitor health and safety performance.
! Ensure that all workers are properly informed and consulted on
hazards and risks of their work.
! Make sure that only authorised people are allowed on to the site.
! Communicate by reports and safety meetings with all concerned at
the site and Powai about all safety matters.
! Give priority to safety in our day-to-day work.
! Follow L&T Rules and Procedures to ensure accident-free, safe
construction site.
SAFETY FIRST Site Safety Officer ________________
Resident Construction Engineer ________________
11th January, 99. Resident Construction Manager ________________

3.2. SHE Structure
The SHE organisational structure of L&T’s E & C Division Safety

Management’s system and personnel responsible for safety
aspects are as follows:
Sr.Vice President (Operation)

and Member of the Board
Cluster Heads
Chief
(Management
Services) Business
Group Leaders
Head
(Project Management/ER&C)
Head
(Safety)
Resident
Construction Managers
Safety Site Safety

Engineers Officers
LEGEND
: Communication / Interaction

3.2.1. Safety Control Organisation Structure
Head
(Safety)
Safety
Engineers
3.2.2. Site SHE Organisation Structure
The Site SHE organisational structure of L&T’s E & C Division

Safety Management system and personnel responsible for
Safety aspects are as follows:
Resident
Construction Managers
Site Safety
Officers
3.2.3 Duties and Responsibilities
3.2.3.1. Management
3.2.3.1.1 The management shall have ultimate responsibility for SHE

management system. The responsibilities include.
• Providing adequate resources essential to the
implementing continual improvement of SHE organisation
system.
• To ensure organisational freedom necessary to implement
the SHE management system.
• Adherence to statutory requirements pertaining to
occupational Safety, Health and Environment.

3.2.3.2. Safety Control Department Responsibilities
3.2.3.2.1. To set up standards for prevention and control of losses

3.2.3.2.2. To participate in safety activities and give full support for the
programme.
3.2.3.2.3. To review and act upon safety records.
3.2.3.2.4. To insist on safety being planned into all the operations
undertaken at all times under any conditions.
3.2.3.2.5. To review an OH&S management programme.
3.2.3.2.6. To review the effectiveness of the provisions of the Safety,
Health and Environment Manual.
3.2.3.2.7. To periodically inspect and audit the site for SHE to provide
training to the engineers and supervisors.
3.2.3.2.8. To identify hazard and carry risk assessment and keep the
information up to date.
3.2.3.2.9. To identify and have access to the applicable legal
requirement and keep the information up to date.
3.2.3.2.10. To ensure communication to all employees and other
interested parties on the SHE requirements including legal
and other requirements.
3.2.3.2.11. To set up an OH&S objectives and consider the above while
setting up the objectives.
3.2.3.2.12. To establish and maintain OH&S management program for
achieving objectives.
3.2.3.3. Resident Construction Manager
He is overall in-charge of the safety of the site, for the

statutory compliance and adherence to the guidelines given in
this manual. In addition to this his other responsibilities are:
3.2.3.3.1. To ensure & maintain safe working conditions and practices

for all employees under his supervision.
3.2.3.3.2. Ensure that contractors follow safe working practices in line
with the company policy and will take steps to rectify.
3.2.3.3.3. To provide adequate training to all personnel working at site.
3.2.3.3.4. To ensure the understanding of the job hazards and safe
procedures before putting them on to the job.
3.2.3.3.5. To maintain good housekeeping at the project site.
3.2.3.3.6. To ensure the provision of adequate personal protective
equipment and their maintenance and proper use.

3.2.3.3.7. To encourage safety suggestions and act upon them

immediately.
3.2.3.3.8. To conduct regular safety meetings.
3.2.3.3.9. To ensure that SHE manual is made available at site and
copies/ abstracts are issued to all concerned including sub
contractors.
3.2.3.3.10. To ensure that sub contractors are given proper instructions
to comply with safety standards and entries are made in the
daily logbook maintained at the site of all verbal instructions
given to the contractors.
3.2.3.3.11. To ensure proper feedback is given to the connected L & T
departments about shortfalls in design etc. from construction
safety point of view, for future actions.
3.2.3.3.12. To ensure First aid arrangement are made and maintained at
work place.
3.2.3.4. Site Engineer
The site engineer is responsible for ensuring the compliance

of the statues and the recommendations given in this manual
by the contractor and sub-contractors working under them. In
addition to this he will:
3.2.3.4.1. Inspect working area regularly.

3.2.3.4.2. Report accidents and near misses immediately to RCM/SSO.
3.2.3.4.3. Ensure that all persons working under him are trained on safe
and proper working procedures by giving toolbox talk.
3.2.3.4.4. Assist the Site Safety Officer in conducting accident
investigation involving his workers.
3.2.3.5. Site Safety Officer
The site safety officer is responsible to ensure the over all

safety of the site. Functionally he will be reporting to the
safety control department and take guidance from them. In
addition he will:
3.2.3.5.1. Promote & implement the SHE manual at project sites.

3.2.3.5.2. Give assistance in solving safety-related problems, and making
recommendations for improving safety.
3.2.3.5.3. Suggest standards to prevent injuries/losses.
3.2.3.5.4. Investigate near miss incident and accident reports and monitor the
site safety performance against L & T’s internal standards.

3.2.3.5.5. Advise RCM to stop work when the need arises.

3.2.3.5.6. Advice on legal requirements affecting safety.
3.2.3.5.7. Maintain liaison with other departments such as Medical and
Training, official bodies such as Factory Inspectorate and
Insurance Companies and outside bodies such as the National
Safety Council, Productivity and Standards Board, etc.
3.2.3.5.8. Propagate safety through leaflets, memos, reports, poster,
notices, etc.
3.2.3.5.9. Provide assistance to all level of management to implement
accident prevention activities.
3.2.3.5.10. Arrange and participate in periodic safety inspection of work
areas.
3.2.3.5.11. Prepare and keep adequate records of accidents and reports
and tendering of advice to prevent recurrences.
3.2.3.5.12. Monitor and man the access and egress to project on the
work site.
3.2.3.5.13. Liase as required with the Fire Watch.
3.2.3.5.14. Conduct Safety meeting at least once a month to discuss
various aspects on safety with sub contractors and clients and
minuted.Initiate Tool-Box talks with workers
3.2.3.5.15. Be important member of the on-site emergency team and
perform duties as mentioned in the emergency plan.

3.2.4. Returns
3.2.4.1. Reporting about Opening/ Closing of Construction Sites
3.2.4.1.1. Objective
In order to conform with norms set in the safety policy, it is

essential to know in advance the opening and closing of a
site.
A detailed procedure is given below for compliance.
3.2.4.1.2. Procedure
3.2.4.1.2.1 This Procedure requires that SCD at Powai should be

informed about opening and closing of a construction site
within seven days of its opening/ closing.
3.2.4.1.2.2 The information to be sent to SCD, Powai shall be filled in
the format annexed to this Procedure.
3.2.4.1.2.3 It should be sent by a fax message (No. 022 - 8581020) for
the attention of Head-Safety Control followed by a
confirmatory copy by post/ courier.
3.2.4.1.2.4 Project Execution Manager at Powai / Baroda shall be
responsible to provide the information. However, RCM/ RCE
shall ensure that the information has been sent to SCD,
upon taking charge of the site.
3.2.4.1.2.5 All construction sites of E & C Division shall be covered
under this Procedure so long as any person/s of E & C
division and/ or its appointed contractors/ agents carry out
activity of any kind at the site.
3.2.4.1.3. Definitions
3.2.4.1.3.1. Opening of a Construction Site
3.2.4.1.3.1.1. An event/day when L&T personnel or L&T’s contractor/s or

L&T’s vendor/ agent/s start carrying out activity of any
kind at a site where construction activities will be further
carried out.
3.2.4.1.3.1.2. For reporting to SCD, man-hours shall be counted
from the opening of the site and all safety procedures
shall apply to the site.
3.2.4.1.3.2. Closing of Construction Site

3.2.4.1.3.2.1. An event/day after which no further activity of any kind

is carried out by L&T personnel or L&T’s contractor/s or
L&T’s vendor / agent/s at the site.
3.2.4.1.3.2.2. RCM/ RCE will stop sending reports to SCD from this day
onward, for the specific site, which is closed.
3.2.4.1.4. This revision:
The annexed form has been revised to request additional

information while opening a site.
3.2.4.1.5 RECORD
Forms Records
Site opening and closing Report CSC – 10 –R2

Annexure -1
Larsen & Toubro Limited Safety Control

Powai, Mumbai E & C Division
To: Head (Safety Control), E & C Division
(A) SITE OPENING REPORT : (Attach separate sheet if required)

1 Name of site/ project
2. Project job no. & Debit code no.
3. Location
4. Complete address
Telephone, V-sat (hotline) & fax

nos.
e - mail address
5. Name of Resident Construction
Manager / Resident Engineer
6. Names of Site Engineers
7. Name of Site Safety Officer

8. Names of contractors & nature/
type of their activities
9. Estimated no. of man-hours

10. Duration of construction activities
11. Safety manual, procedure Available at site /
manual and DACP (Safety -34 ) required at site
12. Whether commissioning is in L&T’s
scope of responsibilities or whether
L&T will provide commissioning
assistance only to the client ?
13. When will ownership of the plant/
facility be transferred to the client?
(a) After mechanical completion.
(b) After commissioning &
Test-run.
14. Date of opening of construction site
15. Any other relevant information
Date: __________ Signature: ________________________________
Name : ________________________________
(Project Execution Manager/ Resident Construction Manager)
Copies to :
: All SBU Heads
: Project Execution Manager - Powai/ Baroda
: Champion of concerned SBU

Annexure 2
Larsen & Toubro Limited Safety Control

Powai, Mumbai E & C Division
To: Head (Safety Control), E & C Division
(B) SITE CLOSING REPORT :
This is to certify that there will be no further construction/ commissioning

activity of any kind on the construction site at
________________________ (location), from _______________ (date
of closing of construction site).
Total no. Of man-hours worked at this site from _______________ (date

of opening of construction site) is ____________________.
I have handed over to Mr. ___________________________* / retained

with me * all safety documents listed in point A (11) of the annexed
form.
Date: __________ Signature : _____________________
Name : _____________________
(Project Execution Manager/
Resident Construction Manager)
Copies to:
: All SBU Heads
: Project Execution Manager - Powai/ Baroda
: Champion of concerned SBU
* [Strike off whichever is not applicable.]

3.2.4.2. Monthly Reporting & Analysis of Mishap at L & T

Construction Sites
3.2.4.2.1.1. This procedure is to report and highlight monthly safety

performance record of L&T sites to the management.
3.2.4.2.1.2. Based on these reports, the management can take
necessary steps and augment safety efforts as required at
the sites.
3.2.4.2.2.1. SSO shall write the correct Accident Data & Man – Hours as
per the standard format given by Safety Control Dept. E &
C Division.
3.2.4.2.2.2. SSO & RCM shall sign report. If RCM is not present, his
representative will have to sign and to be forwarded to
Safety Control Dept. in the first week of every month.
3.2.4.2.2.3. Monthly statistic report are processed and analysed by
Safety Control Dept. and performance is evaluated for
further action. Also it will be published in quarterly safety
bulletin.
3.2.4.2.3 Administration
3.2.4.2.3.1 Site Safety Officer of E & C Division or Main Contractor shall

send the report to Safety Control Dept. by the first week of
every month.
3.2.4.2.3.2 If Site Safety Officer is not present, RCM will be responsible
to send the report to SCD.
3.2.4.2.3.3 If there is nothing to report in a particular month then “
Nothing to report’’ will be written in “ Month under report ‘‘
and the same cumulative data as that of previous month
shall be written.
3.2.4.2.4 Clarification
3.2.4.2.4.1 After an accident to a contractor’s workmen, if another

workmen replace him, then there are two types of man -
hours lost.

3.2.4.2.4.2 ACTUAL man - hours lost, which equals to stoppage of work

by the injured person/s. i e. No. of injured person / s X
no. of hours not worked.
3.2.4.2.4.3 NOTIONAL man - hours lost which equals to no. of hours
not worked ( for medical treatment , etc. ) by the injured
person/s, even if he is replaced/ transferred to other site,
after his recovery from the ailment.
(Total man - hours lost due to stoppage work, as a result of
accident /mishap, by the site work-force may also be
reported as a third parameter, to record overall
consequence of the accident).
3.2.4.2.5 RECORD
Form Reference
3.2.4.2.5.1 Monthly Statistic Report - CSC-02-R1

Annexure
Larsen & Toubro Limited Date of Issue : __________________

E & C Division Project Name & Job No. : __________________
Ref.: CSC-02-MR-R1
MONTHLY STATISTICS REPORT
For the month of ________ Year ________
Accident Data
a Lost time Accidents No. Of Man No. of No. of L&T No. of
incidents hours people Contractors Person reporting
lost Involved involved If any to Govt.
For the month under report ( ____2000)

Cumulative
From _______ 1999 to________ 2000
b Minor Injuries
Cumulative
From _______ 1999 to________ 2000
c Fires No. Of Man No. of No. of Loss No. of
cidents hours person equipment in fires
lost injured damaged Rs. reporting
outside
For the month under report(____,2000)
Cumulative
From _______ 1999 to________ 2000
No. of No. of No. of No. of eqpt. Loss in Total Near
d Other mishaps not covered
Near- First aid person Damaged Rs. miss &
in a, b, c. Miss cases injured First aid
Cumulative
From _______ 1999 to________ 2000
Data for Man hours worked
Details L&T E & C Main Contractors Sub-contractors
(A) (B) (C)
No. of People
Man hours worked
O.T hours
Total Man hours
Grand total of man hours worked during the month ( A + B + C ) :
Cumulative man-hours ( from _________1999 to _________2000) :
( Since the opening of site )
_____________________________ __________________
Signature of Site Safety Officer Signature of RCM
Date: Date :
Note: 1. Report should be legible, properly typed. Copy distribution : 1. Site Safety Officer
2. Standard 48,000 man hours lost is taken 2. Site in charge contractor through RCM
for any fatal accidents as per IS No. 3786-1983. 3. DGM, E & C Division Safety, Powai
3. Reportable accident report is to be sent 4. DGM QAIS Process Cluster Baroda
within 24 hours of occurrence. 5. BUH Powai or Baroda / Champion
6. Head Construction Baroda / Powai
3.2.5. Positive Reporting on Safety At Construction Sites
3.2.5.1. Objective
Procedure Nos. CSC-01 and CSC-02 deal with reporting of

accidents and mishaps at E & C Division construction sites.
These reports give negative information, albeit necessary,
about Safety Performance & Management at the sites and
enables measurement of safety in terms of reduction in
injury/harm/loss.
However, when Safety Performance is good, and injury & loss

are low at a particular site, these negative measurements are
not sufficient to have adequate feedback for managing safety,
because potential for injury/mishap may be high at the site
but likelihood of risk of events may be very low. Hence,
absence of accidents is not a sufficient indication of good
Safety Management and other measurements of Safety
Performance are necessary to have assurance that the
absence of accidents is due to good Safety Management.
3.2.5.2. Procedure
The Procedure deals with formally reporting to the Safety

Control Department (SCD) of E & C Division, at Powai, in
writing, about the positive aspects of safety such as follows in
construction activities at sites.
(a) Compliance to Safety Control Procedures (CSC) in the

Procedure Manual.
(b) Provision and use of APTs to/by L&T and Contractors at
site
(c) Regular On-site training of workmen, mock fire-drills etc.
(d) First Aid and Fire Fighting Training of site personnel
(e) Any additional safety provision at site
(f) Any aspect of safety promotion at site such as Safety
Slogans/essay/quiz competition, safety poster display
etc.
(g) Compliance with statutory requirements
(h) Interaction with the client/contractor on safety matters
like joint safety inspection (weekly)
(i) Achieve milestones such as accident-free 100,000 man-
hours.

Before reporting, RCM/E should ensure that the following

requirements are met:
(I) Compliance/provision being reported must be of

permanent/regular nature, i.e. they must continue at the
site until the site is closed.
(II) Compliance/provision must be seen as having definite

and positive effects on preventing mishaps and personal
injuries at the site.
3.2.5.3. Administration
(a) Whenever a positive action is taken at the site, RCM/E

will send its details to SCD in the form attached to this
Procedure. Both RCM/E and SSO will sign the form.
(b) The information may be sent at any time, as and when
the positive safety action is taken at the site.
(c) Safety Officer from SCD will check the actual provision of
the measure/s reported by RCM/E, when he visit the site.
(d) SCD will record the action and use it for co-relation of
such actions with the Safety Performance of the site and
also use it for safety awards, when instituted in E & C
Division.

Annexure
Positive Safety Measure/Action
Name of Site :
Ref. :
Date :
To: Head Safety Control

E & C Division
L&T-Powai.
From :
We are pleased to report the following positive safety measure/s at our

site:
Sr. Date of action/ Description Whether one-time or

No. implementation Continuous/regular
(Frequency)?
We shall ensure that this measure/practice will continue until the site is
closed.
_____________________ __________________________
Site Safety Officer Resident Construction
manager / engineer
Name: Name:

3.2.6. Daily Log - Book
The Site Safety Officer is required to make the Safety

Inspection of the facility and Observations of the work
methods and procedures adopted by the contractors and their
men and record the same in the daily logbook. The entries
should be shown to the Resident construction Manager for
getting his signature and for prompt proper action
The format of the Daily Log-Book is given in the annexure.

Annexure
Format for Daily Log - Book
SR.
DATE OBSERVATIONS ACTION TAKEN SIGN OF SSO SIGN OF RCM
NO

3.2.7. Safety Promotion and Recognition
3.2.7.1. Display of Safety Performance at Construction Site
One of the Codes of Conduct in the E & C Division - ‘Safety

Policy Statement’ is to promote interest and enthusiasm in
safety efforts through awareness and recognition of safety
performance. This is possible, if all persons working at the
L&T site are informed about the safety performance at the
site. Efforts to correct/improve poor safety performance and
to maintain good safety performance will be put by people at
the site, if they know about the current performance, on
continuous basis.
One of the methods of informing persons working at the site

about safety performance of the site, is by displaying it on a
board which is placed prominently and up-dated daily.
Persons working at the site, when they read the information
on the Board, will feel proud of their good safety performance
and will strive to maintain it.
The objective of this Procedure is to require all

construction sites to display information about the
safety performance of their individual sites.
The Procedure deals with the preparation, installation and

updating of the Display-Board giving up-do-date, correct and
accurate information about safety performance of the
construction site, where the Board is installed.

3.2.7.1.3. Suggested specifications of the board:
Dimensions - 1500 mm L x 1000 mm H

(Dimensions may be reduced
proportion-ately to suit site
conditions but not below 1000
mm L x 800 mm H).
- Number Plates : 230 mm H x 115

mm W
Material : Aluminium (preferable) or G.I.

Sheet
1 mm thick or plywood
5 mm thick
Colour : Background : White

Lettering : Dark Green
Numbers & L&T Logo: Black
Layout : See Annexure for a Specimen
Quantity : One or more depending on the

area of the site
3.2.7.1.4. Location of the Board shall be such that it is visible to

all persons working at the site while they move around
the site.
One of the following locations shall be considered:
* Hung on the outside wall of L&T site office near

entrance to RCM office
* Mounted on a grouted frame at the entrance to the L&T
site.
3.2.7.1.5. Languages of safety information on the Board:
- English or Hindi (top half of the Board)

- Local language (lower half of the Board)

3.2.7.1.6. Administration
(a) Within 15 days from the effective date of this Procedure

RCM/Site In-charge will get the Display Board/s ready
and have them installed at any of the suggested
locations mentioned in 2.2 above.
(b) Nos. of days to be displayed will be from the date of the
last LTA/MI/DI. (See Definitions in 3.8).
(c) The safety performance shall cover
persons/equipment/assets of L&T-Group II (P) and of all
its Contractors at the site.
(d) Responsibility of operating/updating the Board shall be of
the Site Safety Officer (SSO). If SSO is not present at
the site, then RCM or his designated person shall be
responsible for operation/updating of the Board.
(e) Name of the person responsible for operation of the
Board and date of updating shall be clearly shown on the
Board.
(f) SSO/RCM shall update the information on the Board
every day (except on weekly offs) at 9 A.M., after
reviewing information of the previous 24 hours.
(g) Safety Officer from SCD (Powai) shall include, in his
inspection, working of this Procedure, during his site
inspection/audit and check that the information matches
with the one provided through Accident Reports sent to
SCD by the site RCM vide Procedure of existing CSC-01.
(h) Definitions of Lost Time Accident (LTA), Minor Injury (MI)
and Dangerous Incident/Occurrence (DI) are given below
for ready reference.
Lost Time Accident (LTA):
An incident which causes death of a person or which causes

bodily injury to a person due to which s/he is prevented from
working for a period of 48 hours or more immediately
following the incident.
Minor Injury (MI) :
An incident which causes bodily injury/ies to a person, who is

treated by the first-aid facility at the site or by a doctor and
who is permitted to work at the site, immediately after the
first-aid treatment.

Dangerous Incident/Occurrence (DI) :
An incident in which (with or without personal injury) there is

or could have been a damage/loss to property, equipment,
materials of L&T or its Contractor and in the surrounding.
Examples: Fire, gas leak, explosion, vessel/cylinder bursting,
collapse or failure of structure, machine etc., subsidence of
floor, roof, chimney etc. and such incidents.
Personal injury/ies during a Dangerous Incident shall also be

covered separately in LTA or MI as may be the case.

PEOPLE ON THIS DATE
L & T – E & C DIVISION SITE

SITE NAME
HAVE WORKED JOB NO.
WITHOUT LOST TIME WITHOUT MINOR WITHOUT DANGEROUS

ACCIDENT FOR INJURY FOR INCIDENT FOR
Safety Performance Board

D D D
400
A A A
Y Y Y
Annexure
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1200
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350 500 500

1500
3.3. Statutory Requirements:
The Government of India has enacted “THE BUILDING AND

OTHER CONSTRUCTION WORKERS (REGULATION OF
EMPLOYMENT AND CONDITIONS OF SERVICE) ACT, 1996”
AND “THE BUILDING AND OTHER CONSTRUCTION
WORKERS (REGULATION OF EMPLOYMENT AND
CONDITIONS OF SERVICE) CENTRAL RULES 1998” and the
copy can be procured for the site.
In order to facilitate for easy reference for important chapters,

the rules governing the subject of the chapter are also given.

3.4. Prequalification for selection and performance of

Contractors for L & T work
(A) Objective
This procedure is to scrutinise / evaluate L & T Construction

Contractors w.r.t their sutability to work safely on L & T sites.
It is expected that by emloying the contractors who meet the
qualification requirements laid in this procedure, accidents and
dangerous occurences on L & T sites would be minimised. By
following the procedure, L & T Manager should encourage
contractors on safety and make every effort to qualify them by
advising them corrective actions to be taken by them.
(B) PROCEDURE
The Procedure covers basically four situations / status w.r.t. the

contractors at E & C Division sites and these are shown in tables
below :
CONTRACTOR CONTRACTOR PROCDURE

STATUS ACTIVITY NO. CSC-03/
1. New Request for prequalification; /1

(Not qualified in no bidding
safety by L & T)
2. New Bidding for a specific /2
(Not qualified in project
safety by L & T)
3. Existing Working at Group II- /3
(Not qualified in projects site / s
safety by L & T)
4. Existing Not Working at Group II - /4
(Not qualified in projects site / s
safety by L & T)
Procedure for Prequalification in Safety of a New Contractor

( Not bidding for specific project )
1. Contractor desiring to register with L & T E & C Division, approaches

any BU Manager / SAFETY CONTROL, for working on L & T project .
2. Contractor is given a blank of ‘ Contractor Safety Capability
Evaluation ‘ Form (CSCE) - Sample copy attached to this procedure
for reference , excluding Section H of CSCE which he fills and
submits to either Project / Site Manager or Head - SAFETY
CONTROL.

In any case, the original must come to Head – Safety Control and
others retain copies.
3. Safety Control Engineer (SCE) from Safety Control scrutinises the
information and visits the contractor office / sites for inspection, if he
finds more than 80 % of the requirements are met . SCE advises the
contractor about the shortfalls, if any.
4. If 80 % requirements not met, Head – Safety Control reject the
contractor’ s application to register and asks him to resubmit when is
ready to meet the requirements. If the contractor intends to know,
Head – Safety Control will inform the contractor in writing about his
shortcomings in safety qualification.
5. If the contractor qualifies,
- Head – Safety Control will inform the contractor about his
acceptance by L&T for registration.
- Head Safety Control will inform all BUH’s / DGM’s / AGM’s / PM’s
/ SM’s by a memo and a copy of updated list of prequalified
contractors.
6. If during the site inspection of SCE , any shortfall in the qualified
contractor safety capability is observed , he will be instructed to
corect it within a specified time , failing which he will be disqualified.
Then
- Head – Safety Control will inform the contractor about his
disqualification.
- Head – Safety Control will inform all BUH’s / DGM’s / AGM’s /
PM’s / SM’s by a memo and a copy of updated list of prequalified
contractors. Name of the disqualified conractor will be deleted in
this list.
It will be decision & responsibility of PM / SM about the continuation
of services of the subject contractor at the ongoing sites. In any
case, the contractor shall not be awarded any new contract for
work/services, untill he requalifies in safety.
Procedure for Prequalification in Safety of a New Contractor

( Bidding for a specific L & T project )
1. Project / Site Manager will send the CSCE form along with other
documents of RFQ , to all prospective contractors, who are not
qualified in Safety with L & T E & C Division.
2. When PM / SM receives the filled - in CSCE , he will send original to
DGM ( QA & I ), retaining a copy of the same.

3. Same as in Procedure No. CSC-03/1.

6. If the contractor fails to meet the qualification standards of Safety,
DGM ( QA & I ) will inform him accordingly , in writing , with copies
to BUH’s / DGM’s / AGM’s / PM’s / SM’s, who shall not award work
to the said contractor / s at Group II Project sites .
7. Same as No. 6 in Procedure No. CSC-03/1.
Procedure for Prequalification in Safety of an Existing Contractor

( Working at L & T Group II projects site / s )
1. PM / SM at the site / s issues the CSCE form to the contractor and

requires him to fill in and submit it to PM / SM within 15 days.
2. PM / SM will snd the original to DGM - QA & I , retaining a copy of
the same.
3. SCE scrutinises the information given inthe csce and visits the
contractor office site / s. If the Safety requirements are not met
satisfactorily , SCE advises , in writing , PM / SM about the
shortcomings , and sends a copy of the advice to the contractor for
correcting / reinforcing his safety capability.
4. If 80 % of the requirements are not met within 15 days after SCE’s
advice to the contractor, DGM - QA & I rejects the contractor from
qualifying in safety and informs the contractor and BUH’s / DGM’s /
AGM’s / PM’s / SM’s in writing.
It will be decision & responsibility of PM / SM about the continuation

of services of the subject contractor at the on-going sites . In any
case the contractor shall not be awarded any new contract for
work/services, untill he requalifies in Safety.
Procedure for Prequalification in Safety of an Existing Contractor

( Not Working at any L & T Group II projects site / s )
1. All such contractors , who are desirous of working at L & T site, within
one year , are informed by PM / SM about L & T’s requirement for pre-
qualification in SAFETY.

(C) Administration
(a) Books containing 5 sets of CSCE Forms will be sent to all sites
by Safety Control Department . More forms can be obtained
from Safety Control Department. However, if forms are
exhausted, the CSCE should be prepared in photocopy/typed
copy and submitted to Head Safety Control.
(b) SE will periodically check at all E & C Division Sites whether the
contractors working at sites are qualified in Safety by L & T
and advise Sr. V. P. / BUH’ s about the status every quarter.
(D) Definitions / Abbreviations
- BUH : Business Unit Head

- Head–Safety Control : Deputy General Manager, E & C Division.
- SCD : Safety Control Department
- SM : Site Manager
- PM : Project Manager
- SCE : Safety Control Engineer from QA & I
- CSC : Construction Safety Control
- RFQ : Request For Quotation
( Same as ITB - Invitation to Bid )

3.4.2 Rules governing Contractor’s work
(A) Objective
Procedure No. CSC-06 stipulates that the standard Terms &

Conditions (T&C) of HSE should be included in the
contract/purchase orders issued to the L&T site contractors, by the
respective Project/Site Managers of E & C Division
In order to ensure that the managers, engineers, supervisors &

safety officers of L&T and the contractors are constantly made
aware of these T&C, it is necessary that these T&C are available
readily with these persons, as Rules in the form of a booklet,
which are individually issued to each of these persons.
(B) Procedure
This Procedure deals with the issuing of standard Rules of SHE to

all L&T-and contractors-managers, engineers, supervisors and
safety officers, who are concerned with health and safety of their
employees working at the site.
The following actions are required to be taken by RCM/RCE of

L&T/LTCG (in case of site synergy situation).
1. RCM/RCE shall request to SCD adequate no. of copies of the

booklet well in time before any contractor is employed at his
site.(Fifty booklets are being sent with this procedure, for the
on-going sites) .A sample copy of the same is enclosed in the
annexure.
2. REC/RCE shall ensure that the booklet is individually issued to
L&T and contractor personnel who are responsible for
supervising their workers activities at his site.
3. RCM/RCE shall fill up the necessary details and sign them,
and have the person (to whom the booklet is issued) sign, in
the space provided for this purpose.
4. RCM/RCE shall ensure that the persons issued with the
booklet shall have the booklet with them at any time while
they are working at the site, have read and understood the
Rules and have been provided with clarifications as needed.
5. RCM/RCE shall ensure that, additional rules, if any, included
in the contract are incorporated/attached to the booklet
copies before issuing to the contractors.

(C) Administration
1. SCD shall maintain adequate stock of the booklet in Powai.

2. RCM/RCE shall request to SCD for copies of the booklet
allowing adequate time for mailing etc.
3. If the stock of the booklet is exhausted temporarily at the
site, RCM/RCE shall issue photocopy of the booklet from the
contract document and immediately request SCD for
additional copies.
4. During the site visits, Safety Officers from Powai shall check
that the booklets issued to all concerned are available with
them. Safety Officer shall also check that the Rules are
understood by them.
5. SCD shall send 50 booklets with this procedure, to
RCM's/RCE's of the on-going sites.

FOR L&T USE ONLY
CONTRACTOR SAFETY CAPABILITY EVALUATION VENDOR CODE No.
To enable us to assess & evaluate you capabilities in Safety please complete & return to:
LARSEN & TOUBRO LIMITED TELEPHONE : 022-8581401/1411
E & C Division – Safety Control Department TELEFAX : 022-8581020
Saki Vihar Road, P.O.Box 8901, Powai, Mumbai 400 072, India TO BE UPDATED IN
JANUARY EVERY YEAR
SECTION A – BASIC DETAILS
COMPANY NAME ADDRESS FOR COMMUNICATION
MAIN CONTACT NAME / DESIGNATION TELEPHONE NUMBER FAX NUMBER
PERSONNEL RESPONSIBLE FOR SAFETY AT SITE
TYPE OF COMPANY / INDUSTRY / FIRM (TICK AS APPROPRIATE)
PUBLIC PRIVATE GOVERNMENT PARTNERSHIP PROPRIETRY CONTRACTORS OTHERS (SPECIFY)
SECTION B – EVALUATION REQUIREMENTS

SERVICE PROFILE (TICK AS APPROPRIATE)
CIVIL MECH.ERECTION PIPING ELECTRICAL INSTRUMENTATION

INSULATION PAINTING STRUCTURAL OTHERS (SPECIFY)
SCOPE OF APPROVAL
THE SCOPE OF APPROVAL DETERMINES THE NATURE OF YOUR SERVICES YOU INTEND TO PROVIDE TO L&T
SECTION C – SAFETY ORGANISATION
1. Do you provide safety officers at your job sites? Yes / No
Give details, no. of safety officers, their qualifications, their accountability and authrities, their nature of work. (Full-time or Part-
time?)
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
2. Do you nominate trained safety observers among workmen at your job-sites? Yes / No
Give details and account of their effectiveness.

_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
3. Do you have formal / written accident (personal & equipment) reporting & investigation system? Give details and attach blank
forms used in your company. How does the system work?
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
4. Do you keep records of all accidents, mishaps, dangerous occurrences at all your job-sites?
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
SECTION D – SAFETY RECORD / PERFORMANCE

1. Give the following details (for last three years) (incl: your sub-contractors)
Incident No. No. of job-sites No. of man-hours Compensation paid /

Involved worked Loss (Rs.)
a. Minor injuries _____ _____________ ________________ _________________
b. LT accidents _____ _____________ ________________ _________________
c. Fires _____ _____________ ________________ _________________
d. Explosions _____ _____________ ________________ _________________
e. Other dangerous
occurrences (describe) _____ _____________ ________________ _________________
f. Fatal accidents _____ _____________ ________________ _________________
g. Frequency rate ________________ Severity rate __________________

2. Have you paid third party compensation? Give details for the last three years (incl : your sub-contractors)
Year Amount paid Rs. No. of persons Total contract value

Involved for the year (Rs.)
______ _______________ ________________ ___________________

______ _______________ ________________ ___________________
______ _______________ ________________ ___________________
______ _______________ ________________ ___________________
______ _______________ ________________ ___________________
______ _______________ ________________ ___________________
______ _______________ ________________ ___________________
3. Was your company / company official involved in any litigation due to accident / fire etc. at your job sites in the last three years?
Is there any court case pending against your company / company official? Give details.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
SECTION E – ADDITIONAL INFORMATION

1. Give additional information (on safety), if any.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
SECTION F – YOUR PROPOSAL FOR THE SPECIFIC JOB-SITE FOR WHICH ARE BIDDING TO L&T
1. Give details of insurance, legal arrangement etc. you will provide / have provided for in this bid.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
2. Will you indemnify L&T and its personnel against any legal action due to accident, fire, dangerous occurrence at L&T site & its
surroundings? Give details.
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
3.5 Safety Committee
3.5.1. Introduction:
Statutorily (See section 38 of The Building and other construction
workers (Regulation of employment and condition of service) Act
1996) each site should have a safety committee having equaled
number of representatives from management and workers/
contractors. A well-planned safety committee is a great motivator
for safety. It’s primary purpose is to enable management and
workers to work together to monitor the site safety plan, so as to
prevent accidents and improve working conditions on site. Its
size and membership will depend on the size and nature of the
site and upon differing legal and social conditions in the state
concerned, but it should always be an action orientated group of
people in which both management and workers are represented.
The safety committee carrying out a site inspection together
raises the level of safety consciousness at the site.
The procedure for forming the safety committee, scope and

objectives of the committee, meeting procedures, minutes
preparation and circulation and follow up action is listed in
annexure.

Annexure
Formation of safety committee, membership, objectives, meetings,

minutes and follow up action.
1) Formation of Safety Committee

Each site will have one Safety Committee.
Safety Committee will consist of/be represented by site – in –
charge of all contractors / sub – contractors and headed by the L&T
site Manager. This committee will have periodic meetings headed
by L&T Site Manager.
2) Meeting Frequency
a. Meetings of the safety committee and shall be held at least

once in a month, in the second week of each month.
Dates of the next meeting shall be informed to all

members in the preceding meeting, so that the members
can make themselves available for the next meeting.
This is important so that the members find / make time
available to attend the meeting.
b. Special safety committee meeting shall be held as required to

discuss serious accidents, potentially accident – prone
activities and such matters.
3) Scope / objectives of the Safety Meetings
Regular and frequent meetings to discuss the safety and health

programme on site and to make recommendations to management.
Discussion of accident and illness reports in order to make

recommendations for prevention.
Evaluating improvements made.
Examination of suggestions made by workers, particularly by safety

representatives.
Planning and taking part in educational and training programs and

information sessions.
4) Administration
a. Agenda of safety meetings shall be prepared by the L&T safety

officer / site Manager at the site and sent to all participants at
least one week in advance.

Agenda shall include review of MoM of the previous

month, acceptance by all participants (to be recorded)
and record of actual completion dates of action items.

Larsen & Toubro Limited. Site _______________

E & C Division Date of Issue ________
Sheet ____of ____
Minutes of Safety Committee Meeting

held on _______, at the site
for the month of __________’2000
Present
Sr.
Name Company Signature
No.

Larsen & Toubro Limited. Site:________________

E & C Division Date of Issue: _______
Sheet ____of ____
Minutes of Safety Committee Meeting

held on _____________________, at the site
Sr. Particulars of the minutes Action Target Actual

No. (Including recommendation) By Date Comple-
for Tion
action Date of
Action
1 Review of previous MoM held on ______
The next safety committee meeting will be

held on
___________________________ ____________________
Name & Signature of Site Safety Officer Name & Signature of RCM/RCE
Date: Date :
Note: Copy Distribution: 1. Site Notice Board
1. Report should be legible, properly typed. 2. All committee member
3. SCD – Powai
4. Project Manager
5. Safety Champions

3.6 Construction Safety Plan
(A) Objective
(i) This procedure is to inform, familiarise, involve and get

commitment of Project-ites of E & C Division, about L&T’s
concern for and recognition of Safety, Health and
Environment (SHE) during construction, from the very
beginning until the project is completed and handed over to a
client.
(ii) Provisions for SHE during construction of projects have to be
thought about, planned, incorporated and committed by L&T
from the time a tender is submitted to a client, and carried
through in techno-commercial discussions with the client, in
the contract/order document, and in the project execution
such that construction is possible to be carried out in
safe/accident-free manner.
(iii) It is expected that by following this procedure, the Client,
Project Execution and Construction Departments will be
enabled to make adequate provision for safety during
construction.
(iv) ‘Construction Safety Plan’ is meant to be a part of `Project
Safety Plan’ (PSP) which will cover not only construction
safety but also safety in engineering, procurement and
commissioning, i.e. Total Safety Management (TSM) in a
project.
(v) `Project Safety Plan’ will be incorporated as separate
Procedure and Document.
(B) Procedure
The procedure deals with making available General Construction

Safety Plan (CSP-G) to Marketing, Prospective Clients (through
Marketing), Project Execution and Construction Departments of E &
C Division, who have all to play important roles in its
implementation in the steps described below.

(C) Steps for Implementing the Procedure:
Step Event Action Action

No. By
1. Marketing Dept. sends (a) Attach Construction Marketing

proposal/tender to a Safety Plan (CSP-G) to
client the Proposal / Tender.
(b) Provide for safety Marketing

require-ments (Sections
1 to 6 of CSP-G) in the
price quoted to the
client.
(c) Request the client to fill- Marketing

up Sections (7) & (8) of
CSP-G.
2. Client wants to inspect (a) Show the attachments Marketing

the attachments to CSP viz. Safety Manual, Policy
Statement, Procedure
Manual, Terms &
Conditions for
Contractors on Safety, to
the Client. Do not
submit them to the
client.
(b) Provide one copy of SCD

Construction & Procedure
Manuals to Marketing
Department (for client’s
inspection).
3. Technical discussions with (a) Obtain sections (7) & (8) Marketing
the Client of CSP duly filled up,
from the Client prior to
the technical discussions.
(b) If necessary, invite Marketing

Safety Control Dept.,
Project Execution and
Construction Depts. for
discussions on safety
matters with the Client.

Step Event Action Action

No. By
4. Techno-Commercial (a) Adjust the price quoted, if Marketing

discussions with the necessary, for additional +
client provisions for safety Project
according to the informat- Execution
ion provided by the client
in Sections (7)&(8) of
CSP-G
(b) Discuss the above with Marketing

the client, finalise and get +
the client’s commitment Project
on the information in Execution
Sections (7) & (8).
5. Contract/Purchase Order Include CSP-S, which is Marketing

with the client specific for the client in the
CO/PO attaching Sections (1),
(2), (5), (6), (7) & (8) of the
CSP. Sections (7) & (8) will
contain the information and
commitments from the client
in Step Nos. 3 & 4 above.
6. Project Execution Hand over the PO/CO and Marketing

specific CSP (CSP-S) to
Project Execution and Safety
Control Depts.
7. 15 days before (a) Hand over PO/CO with Project

Construction starts (CSP-S) to the Execution
Construction/Resident
Manager
(b) Send copies of Policy SCD

Statement, Construction
Safety Manual, Procedure
Manual to the Resident
Manager (if he does not
have these).
8. Pre-Construction Meeting (a) Invite SCD to participate Resident

at the site to explain CSP-S to the Manager
site personnel, contractors
and the Client.

Like in case of any Company Procedure, TIMELY & SINCERE

ACTIONS by as also CLEAR AND COMPLETE COMMUNICATIONS
among the concerned departments viz. Marketing, Project
Execution, Construction & Safety Control Dept. is key to the
success of this procedure which is essential and important to
achieve accident-free construction sites of E & C Division.
(D) Administration
(i) Safety Control Dept. (SCD) will initially provide copies

of CSP-G and Procedure No. CSC-07 to the Marketing
Managers of E & C Division. Besides, CSP-G and the
Procedure will also be sent out to the recipients of
controlled copies from SCD.
(ii) Copies of the Construction Safety Manual, Procedure Manual,
Policy Statement Placard, Model Terms & Conditions for
Contractors on safety will also be sent to the Marketing
Managers, who have not received them from SCD.
(iii) Clarifications/Suggestions, if any on this Procedure should be
communicated to SCD in writing for subsequent revisions.
(iv) Marketing Department is requested to print/photo copy
(without any alterations/changes) the original CSP for their
future requirement.
(E) Definitions
(i) `Project Safety Plan’ (PSP), of which `Construction Safety

Plan’ (CSP) will be a part will be developed and issued in the
near future.
(ii) CSP-G: `General Construction Safety Plan’ which contains
blanks for a client to fill up in the Section (7) of CSP and does
not have the client’s specific safety requirements in the
Section (8) of CSP.
(iii) CSP-S: `Specific Construction Safety Plan’ which contains
detailed information and commitments in the Sections (7) &
(8) from the client. The cover-page of CSP-S will bear the
name of the site “For __________________Site”.
(iv) SCD: Safety Control Dept. at Powai.

3.7 Accident reporting and Investigation
(A) Objective
(i) Objective of this procedure is to ensure that Safety Control

Dept., E & C Division is notified of all accident as soon as
possible.
(ii) This procedure will also provide a systematic method of
investigating and reporting an accident at construction site
and identify corrective action steps to prevent a
reoccurrence.
(iii) This procedure also outlines the method of communicating
with Safety Control Dept., E & C Division.
(B) Definitions
Fatal : Death resulting from an accident.
LTA (Lost Time Accident):
An injury causing disablement of an injured person beyond 48

hours excluding the days of accident and reporting to work back.
which should also include Sundays and holidays.
(a) Immediate loss of any part of the body or any limb or part
there of.
(b) Crushed or serious injury to any part of the body due to which
loss of the same is obvious.
(c) Any injury which is likely to prove fatal.
(d) Unconsciousness due to accident.
(e) Severe burns or scalds due to chemicals, steam or any other
cause.
Dangerous Occurrences:
(a) Bursting of a vessel used for steam having pressure greater

than atmospheric pressure.
(b) Collapse or failures of any lifting machine (crane, wire rope
hoist, chain pulley block, etc), lifting Tackle (chain sling, wire
rope sling, shackle, clamp, etc.) and lifts (passenger, goods
and service).
(c) Explosion, fire, bursting out, leakage or escape of any molten
metal, hot liquor or gas, which results into injury or material
damage.

(d) Explosion of a receiver or container used for storing any

substance (gas, liquid, solid etc.) at a pressure greater than
atmospheric pressure.
(e) Collapse or subsidence of any floor, gallery, roof, bridge,
tunnel, chimney, Wall, building.
Minor Injury:
An injury, which requires Medical treatment, causing any

disablement of injured person from work less than as mention in
LTA. Person is resumed the site within 48 hours after receiving an
injury.
First aid injury:
An injury, which requires first-aid treatment only without causing

any disablement of the injured person from work. Person is
resumed site within two hours after receiving an injury.
Near - Miss Occurrence:
These are incidents / occurrences wherein a serious accident as

described in 1, 2, 3, 4, and 5 above has not happened but could
have happened or could happen, if the unsafe situation / act
continues, or it did not happen due to absence of a factor, which
could have resulted in the serious accident.
(C) Procedure
The procedure deals with reporting of accidents involving people,

machinery, buildings, structure, surroundings, environment (air,
water, land), dangerous occurrence and near accident & first aid
occurrence which could have resulted in an accident and / or
dangerous situation.
1. Responsibility of reporting - Residence Construction

Manager
2. Reporting - As per distribution given in the forms.
3. Method of reporting - e-mail / by fax / courier

(Preceded by verbal report within 4
hours in case of major mishap /
fatal accident to BUH/ Sr. V P (O) /
DGM (Safety).
4. Report Forms : There are four basic forms:

(i) Form (Accident Report)
- This is for reporting Fatal, Lost Time Accident,

Minor Injuries, Fire & other dangerous
occurrence.
- To be filled by the supervisor / engineer of L & T/
Contractor and sent to his site - in - charge with
copies for L & T Site Manager and others as shown
in the form, immediately within 24 hours.
- If there is any fatalities, an oral report must be
made to DGM (Safety), within 4 hours and
following information must be provided
• The facility name;

• The location of the incident;
• The time of incident;
• The no. of fatalities or hospitalized employees
and their names;
• The name of contact person and his Tel. No.
and;
• Brief description of the incident.
(ii) Form ( Accident Investigation )
- It is for reporting investigation of the accident /

dangerous occurrence already reported in (i).
- It has to be filled in by the SSO / person
investigating or nominated by Site Manager and
copies to be sent as shown in the form within 72
hours.
- When indicated by the severity of the incident,
steps to secure the incident site must be initiated
immediately to ensure the investigating party can
reconstruct the events leading to the incident.
- Individual interviews should be conducted with
each person at the time of the incident.
• The witnesses should be interviewed promptly,

separately and privately.
• The interviewer should explain the purpose of
the investigation to individual.
• The interviewer should ask the witness to give
their account of the events that occurred.

• The interviewer should avoid questions that

give a yes or no answer.
• After the interview, the interviewer should
document any concerns identified.
• The investigation should be directed at
determining the root cause.
• The investigation team must focus on getting
accurate and complete information.
• The investigation will identify corrective
actions, both immediate recovery actions and
long term follow – up actions to prevent the
incident from reoccurring.
(iii) Form (Near Miss)
- It is for reporting Near- miss accident.

- Accident, which does not come under above
category i.e, Lost time accident, minor, first aid
should be send as shown in the form within 24
hours after an accident take place.
- To be filled by the supervisor / engineer of L & T/
Contractor.
(iv) Form (First Aid cases)
- It is for reporting only first aid cases (Please refer

its definition in Section 2.0, Sub Section 2.1,
Clause 5)
- To be filled by SSO / person investigating or
nominated by Site Manager, one copy to be send
to Safety Control Dept. of E & C Division and
others as shown in the form within first week of
the month.
(D) Administration
1. Safety Control Department will send revised procedure with

the forms to all sites. The reports in photocopy or in typed
form should be prepared and submitted to Safety Control
Department of E & C Division within stipulated time frame as
mentioned in the form.
2. In case of Lost time accident, the Site Manager (or Client’s
Project Manager) will have to send separate reports to the

authorities as per the Section 88 of Factory Act 1948.,

besides these internal reports.
3. Employees responsibility :
- Inform immediately to SSO or concern supervisor for
work related illness and injuries (i.e. on the same day).
(E) Records
Form Reference
1. Accident Report CSC-01-R1-AR.
2. Accident Investigation CSC-01-R1-AI.
3. Near miss Accident Report CSC-01-R1-NA.
4. First Aid Accident Report CSC-01-R0-FAAR.

ACCIDENT REPORT E & C Division / SAFETY CONTROL DEPT
(CSC-01-R1-AR NO.__________) To be submitted immediately after the Accident (Within 24 hours)
Project Name & Job no. Exact location of Accident / Incident Date & Time of Incident SBU
Accident that has occurred ( Tick as applicable )

! Personal Accident ! Fire / Explosion ! Mechanical
! Collapse of Structure ! Spillage of dangerous fluids ! Others ( Specify ) :
Event ( Tick as applicable )

! Injury ! Property damage ! Material loss
! Environment pollution ! Others ( Specify ) :
Name of Injured Designation & Token no. Age : ____ Name of Contractor ( with whom he / she
is working ) :
Sex : ____
Brief Description of Accident :
Specify the injury, extent of damage / loss Location of Injury Object causing injury
( e.g. Fatal, loss of fingers, fracture of leg, scald etc. ) ( e.g. right leg, left hand, left eye etc. ) ( e.g. structural material., m/c, tools etc. )
Whether there was any unsafe condition Whether any unsafe act by injured person
Yes ! No ! Yes ! No !
Whether the person was wearing protective equipment Was he under the influence of Alcohol / Drugs
If Yes, relevant PPE used :
Whether medical aid was given Has report been given to authorities
Whether person was hospitalised If Yes, to whom ( Specify ) :
Yes ! No !
Probable cause of Accident & any additional information :
Name of two witnesses and signatures

1. Name : 2. Name :
Date : ( Signature ) : Date : ( Signature ) :
L & T site manager’s remarks

____________________________________
Name of supervisor of L & T / Contractor
Date : ( Signature ) : Date : ( Signature ) :

Note : 1. Please attach sketches or a separate sheet if Copy distribution : 1. Site Safety Officer
2. Site in charge contractor through RCM
space for any column is not adequate. 3. DGM, E & C Division Safety, Powai
2. Report should be legible, properly typed. 4. DGM QAIS Process Cluster Baroda
3. The purpose of accident report is to find out 5. BUH Powai or Baroda / Champion
the causes, not to fix blame on somebody. 6. Head Construction Baroda / Powai
ACCIDENT INVESTIGATION E & C Division / SAFETY CONTROL DEPT
(CSC-01-R1-AI NO.__________) Investigation of the Accidents reported in CSC-01-R1-AR by
persons nominated by L&T site manager ( within 72 hours )
Name & designation of investigating person Project name & Job no. Exact location of Incident
Name of Injured Designation & Token no. Age : _____ Date & Time of Accident
Sex : _____
Accident details ( CSC-01-R1-Accident Report (AR) No. ___________)
What was Injured doing at the time of Accident :
State whether it is Personal Injury / Property damage Whether LTA or Minor or Others Name of Contractor
( Specify value in Rs. )
Whether there was Unsafe Act? Give details
Whether there was Unsafe Condition? Give details
Was he under the influence of alcohol / drug Yes ! No !

The Injured person working Date & Time the person resumed Specify the failure / deviation from
work after accident Safety norms :
Since : ________ Month, ________ Year
Cause of Accident
What immediate actions have been taken to prevent such What actions could be taken to prevent such
accidents : accidents in future :
Investigating Person Contractor / Site in-charge Site Manager
_____________________________ _____________________________ ___________________________

Name Name Name
Date : (Signature) Date : (Signature) Date : (Signature)

3. The purpose of investigation report is to find 5. BUH Powai or Baroda / Champion
out the causes, not to fix blame on somebody. 6. Head Construction Baroda / Powai
NEAR MISS ACCIDENT REPORT E & C Division / SAFETY CONTROL DEPT
(CSC-01-R1-NA NO.__________) It is important that the reporter removes unsafe
condition or stops unsafe act before filling the form
Project Name & Job no. Exact location of Incident Date & Time of Incident SBU
Probable Accident that could have occurred ( Tick as applicable )
! Personal Accident ! Fire / Explosion ! Mechanical
! Collapse of Structure ! Spillage of dangerous fluids ! Others ( Specify ) :
Name of Contractor Brief description of Unsafe Act / Condition observed
Brief description of Incident :
Whether the unsafe practice / Act / Condition was informed to the person/s involved or contractor supervisor or L&T
engineer before filling the form : ! Yes ! No
To whom reported ( Give name of persons ) :
What action was taken after reporting as mentioned above
Name of the reporter with whom he is working / SSO L&T site manger’s remarks
________________________________________
Name
Date : ( Signature ) Date : ( Signature )

3. The purpose of near accident report is to find 5. BUH Powai or Baroda / Champion
out the causes, not to fix blame on somebody. 6. Head Construction Baroda / Powai
FIRST AID ACCIDENT REPORT LARSEN & TOUBRO LIMITED
(CSC-01-R0- FAAR) E & C Division / SAFETY CONTROL DEPT
TO BE SUBMITTED WITHIN 1ST WEEK OF EVERY MONTH
Project Name & Job no. : For the Month of SBU
Sr.No. Date Time Name of Injured Age Sex Name of Contractors

1.
2.
3.
Sr. Type of Injury Location of Injury Object causing Injury Deviation in Safety
No. norms
1.
2.
3.
Brief description about accidents :
1.
2.
3.
Unsafe act Unsafe Condition

1. 1.
2. 2.
3. 3.
____________________________________ ____________________________________
NAME OF REPORTING SUPERVISOR / SSO NAME OF RCM
___________ ___________
DATE: SIGNATURE DATE: SIGNATURE
Copy distribution : 1. Site Safety Officer
Note : 1. Please attach sketches or a separate sheet if space for 2. Site in charge contractor through RCM
any column is not adequate. 3. DGM, E & C Division Safety, Powai
2. Report should be legible, properly typed.
4. DGM QAIS Process Cluster Baroda
3. The purpose of first aid report is to find out the causes, not
to fix blame on somebody. 5. BUH Powai or Baroda / Champion
4. Only those name shall be included who received only 6. Head Construction Baroda / Powai
first aid injury & resume duty within 2 hours.
3.8 SHE Audit
In order to ensure that the site follows all the statutory

requirements, codes and norms, periodic monitoring is required.
The regular and periodic monitoring is also required to find out the
introduction of any makeshift repairs and changes to temporary
construction at work site, which if left unnoticed may lead to
potentially dangerous work situations resulting in losses.
The regular and thorough inspection activities which an operation

undertakes on a frequency consistent with the risk, provides a way
to reduce the potential for these losses through the identification,
analysis and correction of work place hazards before incident
occurs.
Periodic measurement or Audit is more thorough than regular

measurement or Inspection. It takes more time and it measures
the site’s complete SHE management System. Unlike the
Inspection, which is of specific nature, the Audit covers the entire
SHE Management System.
The formats that are in use are given in the annexure
At the end of each chapter, wherever necessary formats are given

for inspection / audit for ensuring the safety of the machinery used
or the method adopted.

Sheet 1 of 6
LARSENT & TOUBRO LIMITED
SAFETY CONTROL DEPARTMENT
E & C DIVISION, POWAI, MUMBAI - 400 072.
SAFETY AUDIT CHECKLIST
SITE : AUDITOR : AUDITEE :
DATE : REFERENCE : L&T SAFETY MANUAL OF E & C DIVISION
SR. REQUIREMENT TO THE COMPLIANCE ACTIVITY NON REMARKS

NO. COMPLIANCE COMPLIANCE
YES / NO NOTE NO.
1. Is the Company Safety Policy displayed at

site office and conference room?
2. Is full time site safety officer deputed at site?
3. Is Site Safety Officer approved by Safety

Control Department?
4. Are construction safety manual & safety

procedure manual available at site?
5. Does the site have safety committee?
6. Are sub-contractors included in safety

committee?
7. Is safety committee meeting held monthly?
SIGNATURE OF AUDITOR : SIGNATURE OF AUDITEE :

Sheet 2 of 6

YES / NO NOTE NO.
10. Are unsafe acts / conditions, accident causes

and recommendations discussed in meeting?
11. Are action by and target date columns

included in minutes of meeting?
12. Are minutes of meeting circulated among

members and copy sent to SCD, Powai?
13. Is accident reporting and investigation

procedure followed at site?
14. Are near miss accidents reported and

investigated?
15. Is safety inspection logbook maintained by

SSO?
16. Is safety inspection signed by RCM?
17. Is SSO conducting toolbox talks at site?
18. Are records maintained?
19. Is site-opening report sent to SCD, Powai?
20. Is safety day / week celebrated at site?
21. Are safety posters displayed at site?
22. Are adequate numbers of first aid boxes

available at site?
i) Site office
ii) One box for every 300 M radius

Sheet 3 of 6

YES / NO NOTE NO.
23. Is ambulance available at site?
24. Is clinic available at site?
25. Is house keeping in order?
26. Are walkways clear from obstruction?
27. Is material stacked properly?
28. Are sufficient dustbins provided?
29. Is work permit system followed at site?
30. Whether all safety precautions taken, which

are mentioned in work permit?
31. Are Personal Protective Equipment (PPE)

provided for employees?
32. Are employees using PPE?
33. Are safety belts used for working at height

above 2 M?
34. Are safety belts anchored to fixed point?
35. Are ear muffs / plugs provided, where noise

level is more than 85 dB?
36. Is safe access / platform provided for

working at height?

Sheet 4 of 6

YES / NO NOTE NO.
37. Are adequate scaffolding provided for

working at height?
38. Is scaffolding checked / inspected before

use?
39. Are sufficient fire extinguishers provided at
site?
i) Near site office
ii) Near stores
iii) Near hot work
40. Are fire extinguishers properly serviced and

validity date marked on it?
41. Are employees trained for operating fire

extinguishers?
42. Whether all lifting equipment / tackles are

marked with their S.W.L.?
43. Are inspection / test certificates of

competent person (s) available at site?
44. Are adequate lifting tackles provided at site?
45. Are trained operators engaged for operating

the equipment?
46. Are lifting equipment / tackles maintained in

good working conditions and record
maintained?

Sheet 5 of 6

YES / NO NOTE NO.
47. Whether proper storage is provided for gas

cylinders?
48. Whether valve protection caps are provided

for gas cylinders?
49. Whether flash back arresters provided for

oxy-acetylene gas cutting set?
50. Whether trolley provided for gas cutting set?
51. Whether proper clamps provided for hose

connection?
52. Are pressure vessels tested / certified by

competent person?
53. Are ELCB's provided for electrical

installations?
54. Are emergency nos. displayed at site?
55. Is emergency vehicle available at site?
56. Are guards of machinery’s in position?
57. Is work place properly illuminated?
58. Are adequate ladders provided at site?
59. Is monthly accident statistics report copy

sent to SCD, Powai?

Sheet 6 of 6

YES / NO NOTE NO.
60. Are accident prevention tools & safety-

related items available at site as per
procedure CSC-08?
61. Is safety performance board displayed at

site?
62. Is positive reporting on safety report sent to
SCD, Powai?
63. Are excavations safe for work?
64. Are excavation barricaded?
65. Is proper slope or shoring provided for

excavation?
66. Whether hand tools are in good working

condition?
67. Are damaged tools discarded?
68. Whether portable electrical tools are in good

working condition?
69. Is earthing provided for portable electrical

tools?
70. Are guards provided for portable grinding

machines?
71. Whether AERB rules followed for

radiography?

3.9 SHE Training:
3.9.1 Safety Tool - Box Meetings/ Talk (TBT) at Construction

Sites
(A) Objective
Awareness of safety in construction, and knowledge about

hazards and their elimination/ minimisation in construction
activities is one of the prime functions of Resident Construction
Manager/ Engineer (RCM/RCE). This awareness is essential to
prevent accidents to man, machine and environment under his
control & responsibility.
In order to prevent accidents, RCM/RCE has to put his

knowledge about safe practices into action, to begin with
himself, and then ensure that safe practices are followed by all,
who are working at his site and particularly by workmen, who
actually carry out the construction activities.
Due to the typical nature of construction activities/sites,

knowledge, culture, skills and attitudes of workmen to safety
vary from site to site and it is necessary for RCM/E to impart to
workmen the knowledge and skill about safe practices in
construction activities, in general and specific to his site.
One of the effective methods, to inform workmen about safe

practices in their work is TOOLBOX TALK/ MEETING. In these
meetings/ talks workmen are informed about hazards involved
in the activities and safe methods of carrying out these
activities. The information must be given regularly, well in time
and in sufficient details. Annexure gives various topics that
could be included in such talks.
(B) Procedure
This procedure spells out the requirement of conducting TOOL-

BOX TALKS (TBT) at E & C division’s sites, their timings, their
frequency, subjects and responsible person/s. The Annexure to
the procedure gives Tool-Box Talks details for some of
construction activities, which are normally done at almost all
construction sites.
Steps to be taken by RCM/RCE to implement this procedure are

as follows:

1. From the effective date of the Procedure, RCM shall

ensure that -
(i) Site Safety Officer (SSO) at his site is trained &
equipped to conduct toolbox Talks. (If SSO, for any
reason is not trained & equipped to do this, he shall
be immediately sent to SCD at Powai for the
training).
(ii) SSO conducts at least two TBT’s every day in the
morning, before activities in the areas start. SSO may
conduct additional TBT’s during the day in areas
where construction activity is likely to start.
(iii) Each TBT shall be for a duration of about 10 minutes
and shall be directly addressed to workmen in a
language they understand.
(iv) TBT shall be on one specific activity on each occasion.
2. SSO shall record in a separate log book, details about the
TBT’s he has conducted, such as date, time, subject of
TBT, language, location and no. of persons attended and
signature of RCM. SSO shall ensure that RCM is informed
about the TBT’s for the day and he takes RCM’s signature
in the log book.
3. SSO shall ensure that the concerned Supervisors or
Engineer/s of workmen attending the TBT’s are present
when TBT’s are conducted.
4. In order to make TBT’s more effective and meaningful,
SSO shall get to know and RCM shall ensure that SSO
knows the nature of activities on which he plans to
conduct TBT, on the previous day, so that he can tailor
TBTs to suit the exact site conditions and hazards.
5. SSO shall use the information annexed to this Procedure
as such or with suitable modification, for conducting TBT’s
on the subjects of TBT’s covered in the Annexure.
6. SSO through RCM shall report on monthly basis to SCD
about no. of TBT’s conducted at his site and their
effectiveness.
7. Safety Engineers (from SCD, Powai) shall conduct TBT’s
when they visit sites.

(C) Administration
1. Uncontrolled copies of this procedure alongwith the

annexure will be sent to all SSOs.
2. Safety Engineer (SE) from SCD shall check up-to-date
logbook records of TBTs conducted by SSO at the site and
communicate his observations in the visit report.
3. SE shall also interact with SSO, during the site visit, on
additional TBTs which need to be included in the annexure
and also about revision in the contents of TBTs in the
Annexure.

3.9.2 Training at site:
Introduction
An effective accident prevention and occupational health hazard

control program is based on proper job performance. When
people are trained to do their job properly, they will do them
safely. Also training is the only way to influence human behavior.
Training Needs
A training program is needed

• For new and redesigned employees
• When new equipment or processes are introduced.
• When Procedures have been revised or updated.
• When new information must be made available and
• When Employees’ performance needs to be improved.
Here are some indications of a need for a good training program.

• Proportionally more accidents and injuries
• High labor turn over
• Excessive waste and scrap
• Company expansion of plant and requirement
Program Objectives
Training programs should be based on closely defined objectives

that determine the scope of the training and guide the selection
and preparation of the training materials. Objective should be
planned carefully and written down. They should indicate what
the trainee is to know or do by the end of the training period.
The general topics covered by SCD in its training program are

given in annexure 1.
Annexure 2 contains the subjects normally covered in supervisors

training program.
Apart from the conventional training program covered in

annexure 1 and annexure 2, there are other types of training
program. Some of the important programs are listed below:
• On –the –job training
• Conference method of watching like problem solving
Conferences.
• Group training techniques
(encouraging participants to share ideas)

Example: Brain storming sessions, case study presentation,

discussions regarding standardisation of procedure.
• Simulation
• Quiz program on specific topic
• Television / screening of films.
The annexure gives the existing program schedule and also a

model training program schedule.

Annexure 1
Safety Control Department – Training Program Content
• Safety philosophy
• Building and other construction work act
• Safety in working at height
• Material handling
• Crane safety
• Safety in welding and gas cutting
• Fire safety
• Personal Protective Equipment
• Video films and discussions
• Electrical safety (Optional)
• Safety in Chemical handling at Construction Site
Participants: Both regular and contractors employees

Annexure - 2
Model Course Contents of Supervisory Training Program
Session 1
Safety and The Supervisor
Safety and efficient production go together.
Accidents affect morale and public relations.
The cities of a supervisor under OSHA.
Session 2
Know Your Accident Problems
Elements of an accident. Unsafe acts, unsafe
conditions, accident investigations, measurements
of a safety performance. Accident costs.
Session 3
Human Relations
Motivation. Basic needs of workers.
The supervisor as a leader.
The alcohol and drug problem.
Session 4
Maintaining Interest in Safety
Committee functions, maintaining good
employee relations. The supervisor’s role in off-
the-job safety.
Session 5
Instruction for Safety
Importance of job instruction. Making a job
Safety analysis (JSA). Job instruction training (JIT).
Session 6
Industrial Hygiene
Environment health hazards. Skin diseases.
Lighting, noise, ventilation, temperature effects.
Session 7
Personal Protective Equipment
Eye protection, face protection, foot and leg
Protection, hand protection. Respiratory protective
Equipment. Protection against ionizing radiation.

Session 8
Industrial Housekeeping
Results of good housekeeping. The responsibility
of the supervisor. OSHA requirement.
Session 9
Material Handling and Storage
Lifting and carrying, handling specific shapes.
Hand tools for material handling. Motorized
equipment. Hazardous liquids and compressed gases.
Session 10
Guarding Machines and Mechanisms
Principles of guarding. Benefits of good guarding.
Types of guards. Standards and codes. OSHA regulations.
Session 11
Hand and Portable Power Tools
Selection and storage. Training in the safe care

3.10 Work Permit System
Objectives :
At L&T - E & C Division construction sites, numerous activities carried out

by L&T and its contractor/sub-contractor personnel need to be done
safely to prevent accidents to men, machine and surroundings. The
‘Construction Safety Manual’ of E & C Division lays down the basic and
minimum requirements related to safety from those involved in these
activities.
However, it is necessary to ensure that there is commitment from the

Managers / Engineers / Supervisors of persons who carry out these
construction activities. Such commitment can be obtained, if standard
and specific safety instructions related to the activities are informed, in
writing to the Managers / Engineers/ Supervisors before commencement
of the activities on each day and they accept the instructions, in writing.
The commitment to follow safety instructions, in writing, is obtained

through ‘Permit System’, which has to commence from the day the first
construction activity starts at site until the last activity. The ‘Permit
System’ is applied to those activities wherein there are higher potential
risks and hazards. These generally are:
- Radiography work permit for NDT (CSCR)

- Cold work permit (CSCP)
For working at height, opening of flanges, manual sand removal,
painting, working on lifting tools/ tackles including chain pulley block,
cranes( EOT, gantry, mobile) etc.
- Hot work permit (CSCW)
For welding/ gas cutting, sand blasting, grinding, running I.C. engines
etc.
- Permit for entry into confined space (CSCC)
For entry into vessel, pit/opening, excavated area etc.
- Permit for working on electrical lines/ equipment (CSCL)
Procedure :
This procedure lays down steps to be taken by RCM/ RCE before and
during the above mentioned activities at construction site.

There are five different ‘Permit’ forms, each dealing with one of the five
activities mentioned above. Each form has certain standard instructions
and space for writing special instructions by RCM/ RCE, related to the
activity and site situation. These instructions have to be clearly
understood by the workers, Manager/ Engineer/ Supervisor and ensured
that they are followed by the persons actually carrying out the concerned
activity. The forms, therefore, require signatures of concerned responsible
persons, implying their commitment to the instructions. The forms also
require communication regarding completion of the ‘permitted’ activities.
After a form is returned stating completion of an activity, the same can
not be carried out again unless the permit is renewed. The permit can be
renewed for maximum 6 days only. Thereafter a fresh permit is required.
Annexure - I to this procedure lists construction activities that require
issue of permits.
Adminstration
RCM/ RCE shall ensure that this procedure is followed as outlined below:
1. RCM/RCE shall inform all contractors about the permit system and
advise them in writing (by letters and notices) that permits are
required to carry out the above mentioned five activities.
2. Contractors shall be advised to apply for permits for the concerned

activity at least 2 hours before it starts (4 hours, in case of
radiography).
3. RCM/ RCE shall issue the requisite permit form noting down special
instructions and if instructions, if any to the contractor’s supervisor,
who will sign on the form as the ‘Initiator’.
4. After the site and persons are ready as per the instructions on the
form, RCM/RCE, shall inspect the work-site and persons for
compliance of the instructions and if instructions are fully complied,
the contractor’s supervisor, RCM/RCE, L&T Engineer and SSO shall
sign the form to permit the form to permit the activity for the period
and date mentioned on the form.
5. During the progress of the activity/ work permitted, the contractor’s

and RCM’s designated Engineer/ Supervisor shall ensure that there
are no deviations from the instructions. RCM/ RCE, SSO or any
Supervisor and Engineer can stop work and cancel the permit

immediately by stating the reason and signing the permit, if they find
any deviations during the progress of work. The same activity can be
carried out again by obtaining a fresh permit from RCM/ RCE.
6. When the activity / work is completed or the period/ date stipulated

on the form has lapsed, RCM/ RCE shall ensure that the contractor’ s
supervisor returns the form (duly signed ) to RCM/ RCE who shall file
it chronologically for future reference.
7. Permit shall only be renewed if the work - site conditions, activity

and persons involved are same.
8. Fresh permit shall be issued if the activity has to be continued after

completion of the period, if the work-site is different, on a new day
or if the work-site conditions change.
9. Only ‘Red Copy’ shall be issued to the contractor’s supervisor and ‘

Yellow Copy’ shall always remain in the Permit Book in L&T’s site
office.
10. Contractors’ supervisors shall be advised by RCM/ RCE to keep the

‘Red Copy’ with them as long as activity/ work is in progress and
‘Red Copy’ may be demanded by any L&T person as a proof for
authorisation of the work in progress.
11. All signatures and notings of the forms shall be done on both ‘Red’
and ‘Yellow’ copies of the form.
12. Samples of the forms for the said five permits are annexed to this
Procedure.
13. Safety Control Department (SCD) will print and send 100 nos. of
each form to all new and on- going sites, before the effective date of
this Procedure. RCM/ RCE shall promptly and well in time request
additional forms to SCD, when required or may get them printed
without any change in the contents of the form.
RCM/ RCE may use photo copies of the blank forms if the originals
are not available, due to unavoidable delays.
14. RCM/ RCE shall ensure that under no normal circumstances, the said
five activities / work shall be carried out by contractors without a
valid permit.

15. RCM/ RCE shall inform SCD, if there is a need for an additional ‘
permit’ for activities which are not concerned in this ‘ Permit System’
and which in RCM/ RCE’s opinion require a permit.
Safety Officers/ Auditors from Powai will inspect/ audit this aspect
when they visit the site.
Annexure – 1
Table for ready reference :
Activity/ Applicable Permit

Type of work CSCR CSCP CSCW CSCC CSCL
Radiography/ N. D. T. √
Working at height √
Working in pit/ vessel √
Sand blasting/ Shot
blasting
Welding/ gas cutting √
Drilling/ grinding √
Running diesel engine √
Working on electrical √
eqpt.
Operating pneumatic √
tools
Hydraulic/ Pneumatic √
testing
Manual sand removal √
Tightening/opening of √
flanges
Spray painting √
Manual painting √
Working on lifting tools/
tackles including cranes √
Note :
* Some times more than one permit is required. While doing
grinding work in confined space requires ‘hot work permit’ as well
as ‘permit for entry into confined space’.

E & C DIVISION Permit No.: -
COLD WORK PERMIT (CSCP)
General Information
Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons involved in Excavation work
1. 4.
2. 5.
3. 6.
Name of Contractor : Name of Incharge:
The following items must be checked before issuing the permit
Item Item
Y N N/A Y N N/A
1 Equipment/work area inspected ¨ ¨ ¨ 11 Proper ventilation and Lighting provided. ¨ ¨ ¨
2 Surrounding area checked / cleaned ¨ ¨ ¨ 12 Sewers, manholes,etc., and hot surfaces ¨ ¨ ¨
up;oil/rags etc., removed nearby covered /sealed/ isolated
3 Equipment blinded / disconnected / ¨ ¨ ¨ 13 Considered hazards from other routine/ non- ¨ ¨ ¨
closed isolated / wedged open. routine operations & concerned persons
4 Equipment completely drained / ¨ ¨ ¨ alerted.
depressurised. 14 Made sure that there are no bldg. whose ¨ ¨ ¨
5 Provide adequate material with which to ¨ ¨ ¨ stability is affected by excavations
shore the sides of excavations 15 All persons provided with proper PPE ¨ ¨ ¨
6 Gas / Oxygen deficiency test done ¨ ¨ ¨ 16 Equipment electrically isolated / Grounded ¨ ¨ ¨
( Oxygen level -19.6% - 23%) and tagged
7 Precautionary tags/boards provided ¨ ¨ ¨ 17 Sides of excavations are sufficiently shored ¨ ¨ ¨
8 Confirm the locations of the Fire ¨ ¨ ¨ /are sloped back to 45
0
hydrant mains/ Electrical cable/ Service 18 Area cordoned off ¨ ¨ ¨

lines/ Drainage system / water mains, 19 Ensured that there is no spoil or eqpt. close ¨ ¨ ¨
etc. to the edge of the excavations.
9 Provide adequate ladder for getting in ¨ ¨ ¨ 20 Made arrangement necessary to prevent ¨ ¨ ¨
and out of the excavations vehicles driving into the excavations.
10 Used the method of work for putting in ¨ ¨ ¨ 21 Are workers briefed about the hazards? ¨ ¨ ¨
shoring which protects the shorer
Additional permit required and / or attached:- No ¨ Yes ¨ ( If yes specify:- )
Daily Visual Inspection
To be signed only after
Time / Period
Date of Signature of Signature of completing the job
Remarks
Work Site Engineer RCM/RE Signature of Signature
From To
Site Engineer of RCM/RE
Special Instructions :
1. This permit must be available at the work site at all times.
2. Location & description of work must be clearly indicated by the permittee.
3. Terms applicable must be clearly indicated by the permittee.
4. All precautions given in permit must be strictly adhered to by the permittee.
5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.
6. Permit renewal – for not more than 7 times including the issue date.
7. Permit shall be returned to issuer after completing the job.
Additional Precautions required / Remarks, If any :
TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE
All the points mentioned in the above checklist have been checked & found OK
____________________________________ ___________________ ________________ ________________________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)
TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.

Permit is hereby returned after completing the job & ensuring safe removal of men & material.
__________________ _____________ __________ ____________
(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)
CONFINED SPACE ENTRY PERMIT(CSCC)
General Information
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons entering into confined space

1. 4.
2. 5.
3. 6.
Name of Contractor : Name of stand by Person:
Item Item
Y N N/A Y N N/A
1 Equipment/work area inspected ¨ ¨ ¨ 9 Proper ventilation and 24v ¨ ¨ ¨
2 Surrounding area checked / cleaned ¨ ¨ ¨ Lighting / handlamp provided.
up;oil/rags/grass etc., removed 10 Stand by personnel provided for vessel ¨ ¨ ¨
3 Equipment blinded / disconnected / ¨ ¨ ¨ entry.
closed isolated / wedged open. 11 Considered hazards from other routine ¨ ¨ ¨
4 Equipment completely drained / ¨ ¨ ¨ / non-routine operations & concerned
depressurised. persons alerted.
5 Equipment properly steam purged. ¨ ¨ ¨ 12 Proper means of exit provided. ¨ ¨ ¨
6 Equipment water flushed. ¨ ¨ ¨ 13 All persons provided with proper PPE ¨ ¨ ¨
7 Gas / Oxygen deficiency test done ¨ ¨ ¨ & APT (i.e. life line)
( Oxygen level -19.6% - 23%) 14 Proper portable ladder provided ¨ ¨ ¨
8 Equipment properly tagged ¨ ¨ ¨ 15 Suitable scaffolding provided ¨ ¨ ¨
16 Means of exit available ¨ ¨ ¨

Testing Record
To be signed only after completing
Time / Period Meter Reading Signature of
Date of Signature of the job
Site
Work Flammability O2 Toxic Gases RCM/RE Signature of Site Signature
From To Engineer
% Content % PPM Engineer of RCM/RE
____________________________________ ___________________ ________________ ________________________
__________________________________ ___________________ ________________ ________________________
GENERAL ELECTRICAL PERMIT(CSCL)
General Information
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons working on electrical equipment

1. 4.
2. 5.
3. 6.
Item Y N N/A Item Y N N/A
1 Equipment locked out ¨ ¨ ¨ *13 Workers insulated from ground by ¨ ¨ ¨
*2 Caution notice provided near the place of ¨ ¨ ¨ insulating material covering any
work adjacent metal / energized circuits.
3 Surrounding area checked / cleaned ¨ ¨ ¨ 14 Person certified and trained ¨ ¨ ¨
up;oil/rags/grass etc., removed 15 Metal hand tools used are electrically ¨ ¨ ¨
4 Isolator / Breaker switched off ¨ ¨ ¨ insulated
5 Fuses removed / Breaker withdrawn ¨ ¨ ¨ 16 All metal and loose clothing removed ¨ ¨ ¨
6 Aux. Supply (Diesel generator) switched ¨ ¨ ¨ from person doing the work.
off. 17 Hydraulic / air / Gas / Steam / acid ¨ ¨ ¨
7 Transformer isolated from both ends. ¨ ¨ ¨ valves closed.
8 Equipment earthed / earthing truck ¨ ¨ ¨ 18 Appropriated fire-fighting eqpt. ¨ ¨ ¨
inserted / earthing rod put. Provided.
9 All person provided with proper PPE. ¨ ¨ ¨ 19 Temporary connection required? If so, ¨ ¨ ¨
10 Adequate lighting provided ¨ ¨ ¨ Load________ Amp
*11 Barrier established to prevent inadequate ¨ ¨ ¨ 20 Test meter is calibrated and checked ¨ ¨ ¨
entry. against known energized source
12 Verify circuits de-energized and capacitor ¨ ¨ ¨ before checking circuit
shorted
Daily Visual Inspection
Time / Period To be signed only after completing the job
Date of Signature of Signature of
Remarks Signature of site Signature of
Work From To site engineer RCM/RE
engineer RCM/RE
1. This permit must be available in three copies two for initiator and one for issuer.
7. Permit form shall be returned to issuer after completing the job.
8. (*) used only for energized equipment.
9. Use proper PPE while working with energized equipment / Non energized equipment
__________________ __________ ________ ____________
______________________ _________ ________ _____________
HOT WORK PERMIT(CSCW)
General Information
Nature of work :________________________________________________________________________________
Location of work : ________________________________________________________________________________
Name of Persons involved in Hot work

1. 4.
2. 5.
3. 6.
1 Equipment / work area inspected ¨ ¨ ¨ 11 Proper ventilation and Lighting ¨ ¨ ¨
2 Surrounding area checked / ¨ ¨ ¨ provided.
cleaned up;oil/rags/ grass etc., 12 Sewers, manholes,etc., and hot ¨ ¨ ¨
removed surfaces nearby covered /sealed/
3 Equipment blinded / disconnected ¨ ¨ ¨ isolated
/ closed isolated / wedged open. 13 Considered hazards from other routine/ ¨ ¨ ¨
4 Equipment completely drained / ¨ ¨ ¨ non-routine operations & concerned
depressurised. persons alerted.
5 Equipment properly steam purged. ¨ ¨ ¨ 14 Proper means of exit provided ¨ ¨ ¨
6 Equipment water flushed ¨ ¨ ¨ 15 All persons provided with proper PPE ¨ ¨ ¨
7 Gas / Oxygen deficiency test done ¨ ¨ ¨ 16 Equipment electrically isolated / ¨ ¨ ¨
( Oxygen level -19.6% - 23%) Grounded and tagged
8 Precautionary tags/boards ¨ ¨ ¨ 17 Suitable scaffolding provided ¨ ¨ ¨
provided 18 Area cordoned off ¨ ¨ ¨
9 Fire water hose/ portable ¨ ¨ ¨ 19 Flash back arrester provded to gas ¨ ¨ ¨
extinguisher/ nozzle provided cutting set
10 Shield against spark provided ¨ ¨ ¨ 20 All the drain inlets(if any) been closed ¨ ¨ ¨

Testing Record
Time / Period Meter Reading Signature of Signature
Date of the job
Site of
Work Lower Explosive Upper Explosive Signature of Site Signature
From To Engineer RCM/RE
Limit % Limit % Engineer of RCM/RE
____________________________________ ___________________ ________________ ________________________
__________________________________ ___________________ ________________ ________________________
RADIOGRAPHY WORK PERMIT(CSCR)
General Information
Location of work :________________________________________________________________________________
Source strength: ___________________________________ Curie: ____________________________________
Name of Persons involved in Radiography work

1. 4.
2. 5.
3. 6.
Name of Radiography agency : Name of Incharge of Radiography agency:

1 All the persons at the site ¨ ¨ ¨ 6 Radiographer has valid certificate from ¨ ¨ ¨
informed/ removed from the area Radiation Protection Service Division,
2 Area around the source of ¨ ¨ ¨ BARC
radiation cordoned off with rope/ 7 Radiation survey meter is in working ¨ ¨ ¨
chords condition
3 Radiation warning symbol/ boards ¨ ¨ ¨
displayed around radiography
work/ on ropes & chords
4 Radiographer worn radiation ¨ ¨ ¨
badges during testing
5 Radiography camera and carrying ¨ ¨ ¨
box having radiation symbol

Daily visual Inspection
Time / Period Signature of Signature
Date of the job
Remarks Site of
Work Signature of Site Signature
From To Engineer RCM/RE
Engineer of RCM/RE
5. The permit shall be submitted 4 hours before carrying out radiography to RCM/RE, L&T for his authorisation.
____________________________________ ___________________ ________________ ________________________
__________________________________ ___________________ ________________ ________________________
3.11 Safety of L&T Visitors to Construction Sites
(A) Objective
L&T - E & C Division construction sites are visited by a number of

persons who are not normally working at the sites and who are not
familiar with the site conditions and activities.
Safety of visitors at L&T construction sites is equally important as

that of regular persons on these sites. For this, it is necessary to
make all visitors aware of the basic/minimum safety rules, before
they enter the site, and specific/working safety rules while they
work on / go around the site.
(B) Procedure
This Procedure sets out safety guidelines and working procedures

which are considered as the minimum standards applying to all
`visitors’ entering L&T - E & C Division construction sites.
These L&T - E & C Division guidelines are intended to supplement

the applicable laws and regulations and state some of the practices
required of `visitors’ on L&T E & C Division construction sites.
Term `visitors’ includes all persons who are not regularly

employed by (registered/on the role of) L&T or its contractors/sub-
contractors, i.e. `visitors’ include all persons who enter L&T sites
for discussion and/or for carrying out work/activity on behalf of
suppliers/vendors of L&T or its contractor/sub-contractors.
`Visitors’ also include all other L&T employees.
(C) Administration
It is responsibility of RCM/RCE to ensure that the following steps

are taken whenever he permits a visitor into his construction site.
1. RCM/RCE shall permit only authorised persons of companies /

vendors / suppliers to enter the L&T construction site. (This
is to ensure that such persons have knowledge about the
equipment/material they carry and have adequate insurance
coverage).
2. Visitors shall be advised by RCM/RCE to read the short
version of “Safety Guidelines for L&T Construction Site
Visitors”, given in Annexure-I. This shall be available with

RCM/RCE. (Safety Control Department will send six laminated

prints of the short version to all construction sites).
3. RCM/RCE shall take an undertaking from visitors that they
have read L&T’s safety guidelines/rules/procedures before
they do any kind of work in the `construction area’.
4. If the site is within the client’s premises and the entry pass is
issued by the client’s security staff, then RCM/RCE shall
ensure that visitors, who are not familiar with the site
conditions and safety rules/procedures, shall be met at the
entrance of the L&T site (not necessarily at the client’s main
gate) and escorted in and out of the site by an L&T
representative of RCM/RCE.
RCM/RCE shall arrange to prominently display “Safety

Guidelines for L&T Construction Site Visitors” at the client’s
gate where entry passes are issued to the visitors to the L&T
site.
5. RCM/RCE shall show clearly a `safe route’ to his office from

the entrance of the site, by clearly and prominently displayed
signboards marked “Site Office”. While walking on the `safe
route’, visitors shall not be required to wear protective
equipment such as helmet, etc. However, if these are
required, then RCM/RCE shall ensure that these are issued at
the entrance of the site.
6. Visitors permitted for discussion/meeting on the site, shall be
restricted to stay inside the site office.
If however, they are required to go around in the
`construction area’, where construction activities are going
on, they shall be issued by RCM/RCE, the necessary
protective equipment like helmets, safety shoes, gloves etc.,
depending on the nature of hazards present in the area.
They shall always be accompanied by a member of the RCM’s

staff at the site, while they are inside the construction area.
7. Visitors representing vendors/suppliers and L&T officers, who

are required to carry out work such as installation, inspection,
testing, commissioning or any kind of supervision which may
also require their independent presence in the construction
area, shall be made aware of the site safety rules by
RCM/RCE and advised to read and follow the L&T

`Construction Safety Manual’ and the relevant procedures of

the `L&T Procedure Manual’.
These visitors shall be issued all necessary PPEs or shall be

advised to bring their own PPEs and wear them before they
enter the construction area and start working.
RCM/RCE shall also ensure that these visitors have the

necessary insurance coverage for themselves and tools etc.
which they bring into the site.
These visitors shall be considered as if they are L&T-

contractor’s employees for all safety matters at the site.

Annexure -1
Safety Guidelines for L&T Construction Site Visitors
The following rules are the minimum L&T standards applicable to all
visitors to this site and are supplemental to statutory laws &
regulations. If any doubt, please check with L & T - E & C Division
Resident Construction Manager / Engineer (RCM/E) or his staff.
1. Visitors shall enter into and work on this site at their own risk and
shall have own adequate insurance cover.
2. Visitors shall follow advice of RCM/E with respect to more detailed

Safety Rules & Procedures, which visitors shall request for.
3. Smoking is strictly prohibited on this site.
4. Possession of illegal drugs and paraphernalia, intoxicating

beverages, fire arms chemicals/ solvents and other weapons are
prohibited. These may be searched by L&T and visitors having
these shall be immediately removed from the site.
5. Horseplay can be dangerous and is prohibited.
6. Littering and spillage of any kind is forbidden for maintaining

house-keeping.
7. Entry of chemicals / solvents, gas cylinders, photographic

equipment, tools / gadgets / instruments require prior written
permission from RCM/E.
8. Wearing of Personal Protective Equipment (PPE) is necessary

wherever required/directed by L&T.
9. Visitors shall read and follow L&T’s `Construction Safety

Manual’ and `Procedure Manual’, if he is required to carry out
installation, inspection, testing, commissioning or any kind of
supervisory work on this site.
10. Visitors shall make available RCM/E, Material/Equipment Safety

Data Sheets for Materials/Equipment permitted to be carried by
them and shall be trained to use them suitably.
11. Visitors shall immediately report to RCM/E, accidents/injuries,

unsafe conditions/near-misses and use of L&T’s fire fighting
equipment.

PART II: SHE – Implementation
4. Concept of Accident Prevention:
Any accident prevention Programme is based on Hazard Control

Programme. The Hazard Control Programme must be carefully planned
and be logical. Programme objectives and safety policies need to be
established. Responsibility for the hazard control Programme needs to be
determined. Specific steps to identify and control hazards need to be
performed.
Accidents and Hazard Control
Hazards are a major cause of accidents. A workable definition of

hazard is any existing or potential condition in the work place which,
by itself or by interacting with other variables, can result in deaths,
injuries, property damage, and other losses. This definition carries
with it two significant points.
! A condition does not have to exist at the moment to be classified as

hazard, only when total condition is considered then hazardous
condition is to be taken in to account.
! Hazard may result not only from independent failure of work place
components but also from one work place component acting upon
or influencing another.
Effects of Hazard on the Work Process:
In a well-balanced operation, workers, equipment, and material

interact within the work environment to produce a product or perform
a service. When all these function smoothly the productivity is the
highest. But if one of the components does not function to the
desired level then there would be disruption resulting in loss of
productivity.
Hazard Control and Productivity Improvement:
The process of identifying and eliminating or controlling hazards in the

work place is one way of optimising a company’s human, financial,
technological, and physical resources. Hazard Control, like productivity
improvement, is a strategic process. To be effective, it must be
Concept of Accident Prevention 1

integrated into the day to day activities and management systems of

the organisation and must become institutionalised – an operating
norm and a strategic part of the company’s culture.
Determining Accident Factors:
In order to set realistic goals for its process, the company should first
determine the major factors likely to cause loss of control. It should
determine where these factors are, their importance and their damage
causing potentials so as to evolve control measures, which could be in
the form of process/ work innovation etc.
Hazard Control and Management:
Controlling hazard is a team effort involving all the departments. To

co ordinate the departmental activities, a Programmeme of Hazard
Control is necessary. Those involved in establishing hazard control
Programmeme must take into cognisance the inter relationships
between the Worker – Equipment – Environment system as shown in
the figure below:
WORKER
T
A
PERFORMANCE
S
EQUIPMENT ENVIRON-
MENT K
Figure on next page illustrates, an accident can intervene between the

system and the task to be accomplished.

WORKER
A
C T
C
I
A
PERFORMANCE S
D
EQUIPMENT ENVIRON E K
MENT N
T
The worker performs three basic functions as Sensor, Information

Processor and Controller.
Equipment should conform to all the norms.
Special consideration must be given to environment factors, such as
layout, maintenance and house keeping, proper illumination,
temperature etc that might detract from the comfort, health and
safety of the worker.
Accident Causes and their Control:
Accidents are caused. Close examination of each accident situation

shows that it can be attributed, directly or indirectly to one or more of
the following:
! Oversight or omissions or malfunction of the management system.
! Situational work factors like tools etc.
! Human Factor, worker or other person.
! Environmental Factors like noise etc.
Human Factor is the unsafe act of the injured or other person

resulting in the accident. The unsafe act of a person may be due to
several factors such as physical deficiency, lack of knowledge or skill,
mental deficiency like lack of concentration, aptitude to the particular
job etc.

Human error is eliminated by:

! Giving correct job method and procedure
! Providing proper training
! Considering worker performance with his physical characteristics
and fitness
! Correcting potentially dangerous situation and
! Providing proper and effective supervision.
Situational factors are another major cause of accidents. These factors

are those operations, tools, equipment, facilities and materials that
contribute to accidents situation. These may be defect in design, poor
sub standard construction, improper storage of hazardous material
and inadequate planning, layout and design.
Environmental factor includes physical category like noise,

temperature, radiation, etc. chemical category like toxic release etc
and biological category like contact with bacteria etc.
Situational and environmental hazards enter the work place from

many sources like procuring material and employee’s negligence in
following safety norms and rules.
4.1 Principles of Hazard Control:
Hazard control is the function directed toward

• RECOGNISE
• EVALUATING,
• ELIMINATING,
or at least reducing, the destructive effects of hazards emanating from
human errors and from the situational and environmental aspects of
the work place. Its primary function is to locate, assess, and set
effective preventive and corrective measures for those elements
detrimental to operational efficiency and effectiveness.
The process exists on three levels, namely National (laws, regulations

etc), Organisational (management of hazard control Programmeme,
safety committees etc) and component (worker – equipment –
environment).

Process Of Hazard Control:
An effective hazard control Programmeme has six steps or

processes, namely:
! Hazard Identification and Evaluation (through process information
giving the hazard inherent to it, previous inspection reports, and
accident reports and hazard analysis.)
! Ranking Hazards by Risk (consequence and probability) (through
ranking hazard by risk taking into consideration the consequence
and severity, the probability of its occurrence and the worker
exposure and risk assessment).
! Management Decision Making ( providing management with full
and accurate information, including all possible alternatives, so it
can make intelligent, informed decisions concerning hazard
control like training and education, for better methods and
procedures, equipment repair or replacement, environmental
controls etc)
! Establishing Preventive and Corrective Measures (actual
installation of administrative and engineering e.g.: isolation of
source, lockout procedures, design, process or procedural
change, monitoring and warning equipment, chemical or material
substitution).
! Monitoring ( to locate new hazards and assess the effectiveness
of existing controls through inspection, industrial hygiene testing
and medical surveillance )
! Evaluating Programme Effectiveness ( by assessing financial
requirements and the benefits to be achieved through reduction
of medical expenses, damages to machinery and material and
improvement in efficiency)
Organising an Occupational Safety and Health Programme:
The purpose of an hazard control Programme organisation is to assist

management in developing and operating a Programme designed to
protect workers, prevent and control accidents, and increase
effectiveness of operations. The schematic diagram given below gives
the major organisational components of a hazard and loss control
Programme.

Identification and Company policy

evaluation of hazards
Programme objective
Monitoring Programmes
Assignment of
Maintenance programmes Responsibility and Authority
Housekeeping Adequate Physical and

HAZARD
Economic Resources
Standard compliance CONTROL
Safety committees
PROGRAMME
Accident Investigation
Employee orientation and
Evaluation of Programme involvement training and
effectiveness education
Supervision
Programme Enforcement
Detailed discussions on various Hazards control measures are given in

the following chapters.
4.2 Off the Job Safety:
Essential off the job safety involves employees, and is a term used by
employers to designate that part of their safety Programme directed
to the employees when they are not at work.
The principle aim of this Programme is to get an employee to follow

the same safe practices while pursuing outside activities as used on
the job.
This Programme could include employee, his family and community

involvement and can include contest, picnic etc. To make it effective
it should be well designed i.e. subjects well chosen and executed.

5. SITE PLANNING AND LAYOUT
5.1 Site layout
A badly planned and untidy site is the underlying cause of many

accidents resulting from falls of material and collisions between
workers and plant or equipment. Space constraints, particularly in
urban work sites, are nearly always the biggest limiting factor and a
layout, which caters best for the safety and heath of workers may
appear to be difficult to reconcile with productivity. Proper planning
by management is an essential part of preparation and budgeting
for the safe and efficient running of a construction operation.
Before work even begins on site, thought needs to be given to:

• The sequence or order in which work will be done and to any
especially hazardous operations or processes.
• Access for workers on and around the site: Routes should be
free from obstruction and from exposure to hazards such as
falling materials, materials-handling equipment and vehicles.
Suitable warning notices should be posted. Edge protection will
be required at the edge of floor openings and stairs, and
whenever there is a drop of 2m or more.
• Routes for vehicular traffic: These should be “one way” as far
as practicable. Traffic congestion prejudices the safety of
workers from unsafe drivers.
• Storage areas for materials and equipment: materials need to
be stored as close as possible to the appropriate workstation,
e.g. sand and gravel close to the cement-batching plant, and
timber close to the joinery shop. If this is not practicable, it is
important to schedule the arrival of materials;
• The location of construction machinery: This is usually
dependent on operational requirements so that tower cranes
are subject to constraints such as their radius of operation, and
pick-up and unloading points. The objective should be to avoid
the need to slew the load over workers.
• The location of trade workshops: These are not usually moved
after they are built.
• The location of medical and welfare facilities. On large sites
sanitary facilities for both sexes should be provided at several
locations
Site planning and layout 1

• Artificial lighting: At places where work continuos or workers

pass after dark.
• Site security: The site should be fenced in to keep out
unauthorized persons, children in particular, and to protect the
public from site hazards. The type of fencing will depend on the
location of the site, but in populated areas it should be at least
2m high and without gaps or holes. Overhead protection will be
necessary if tower crane loads pass over public thoroughfares.
• Arrangements to keep the site tidy and for the collection and
removal of waste.
• The need for low-voltage electric power supplies for temporary
lighting, portable tools and equipment
• Training needs of both workers and supervisors.
5.2 CONSTRUCTION DETAILS:
After preparing the layout of the site, it is essential to program

construction activities, detailing
• Sequential order of construction

• Plans about layout of temporary construction site buildings, etc.
• Action taken toward planning and co – ordination activities between
different operations and crafts.
• Access to work areas.
These will enable the proper utilisation of the space, unnecessary wastage
of material due to prolong storage, maintenance of better housekeeping
and hiring of costly equipment and skilled personnel for a minimum
period.
5.3 IN – BUILT SAFETY MEASURES:
At the planning stage itself safety should be integrated in all the planned
activities. The material for construction, the machinery to be used and
the method of construction should all be evaluated with reference to the
site, the type of people to be engaged, the infrastructure available and
the environmental conditions and adequate in built safety measures and
work methods should be evolved.
Other measures like Safety Indoctrination and Safety Education,

delegation of safety responsibilities down the line, integration of safety
into operating methods and procedures will improve the quality of work
and help in preventing accidents and dangerous occurrences at the site.

5.4 HOUSE KEEPING:
Many accidents occur at the site due to tripping, slipping or falling over
materials and equipment which have been left lying around, and stepping
on nails which have been left projecting from timber. Good house
keeping is an important element of accident prevention. It should be
planned at the beginning of the job and carefully supervised until the final
clean-up while handing over the site to the client.
It is recommended to have a regular clean up in all job sites. However,

house keeping should be the concern of all supervisors and engineers in
their respective area of working and not left for the clean up crew. In
any case, house keeping should be a part of daily routine with clean up
being a continuous procedure.
In general rubbish and scrap should not be left at the work site.
Gangways, working platforms and stairways should be clear of equipment
and materials, not in immediate use.
Simple rules for good house keeping are as follows:
1. Storage areas : All materials should be maintained in neat

stockpiles with well laid aisles and walkways for ease of access.
There shall not be any projections in the walkways.
2. Work areas: loose materials, scrap, tools, etc shall not be allowed
to be lying in the working areas especially in the vicinity of ladders,
ramps stairs, etc. This is more important at heights where the loose
materials are liable to fall down.
Spills of oil and grease should be removed immediately.
An effective means like provision of receptacles should be provided
to store waste and scrap pieces.
3. Protruding Nails : Protruding nails in wooden pieces is a chronic

problem in civil sites. It is worthwhile to have one or two helpers
continuously for retrieving protruding nails.
4. Scrap yard : Wooden scrap yard should be well away from any
gas cutting or welding operations and 'No smoking' shall be strictly.
ensured. All other combustible wastes like cotton wooden boxes,
empty paint tins shall be disposed off safely within a reasonable
time.

5. Lighting : Adequate lighting should be provided in and around all

work areas, passage ways, stairs, ladders & other areas used by
personnel.
6. Openings in floors : All openings in floors where our workmen.

are liable to work or even pass through shall be either closed or
barricaded. If they are closed, a visible warning sign shall be kept
to indicate the open . sing below the cover.
7. The approach road from and to the work site shall never be
blocked by parking vehicles or stacking materials, etc. thus
blocking the movement in case of emergencies.

5.5 SAFETY AT STORES:
The handling, storage and transportation of hazardous materials are dealt

at the appropriate chapters.
In general the following should be adhered to:
• In case of storage of flammable or toxic substances, adequate

ventilation should be provided.
• Illumination should be proper and should confirm to the relevant rules
and standards.
• Adequate draining facility should be provided to avoid flooding.
• There should be sufficient passage provided for easy movement of
material and lifting machinery.
In addition to above requirements, the provisions under Rule 51 of the

Building and Other Construction Workers ( Regulation of Employment and
conditions of Service ) Central Rules, 1998 should be complied with.
Since it covers the stacking of all construction material, this rule is given
below:
Stacking of materials- The employer shall ensure, at a construction site

of a building or other construction work that-
(a) All building materials are stored or stacked in a safe and orderly
manner to avoid obstruction of any passageway or place of work;
(b) Material piles are stored or stacked in such a manner as to ensure

stability;
(c) Material or equipment is not stored upon any floor or platform in

such quantity as to exceed its safe carrying capacity;
(d) Material or equipment is not stored or placed so close to any edge of

a floor or platform as to endanger the safety of persons below or
working in the vicinity.

6. Civil work
6.1 Blasting
The transportation, storage, handling & use of explosives are governed

by Explosives Act and The Building and Other Construction Workers
(Regulation of Employment and Conditions of Service) Central Rules 1998
(Rules 212 and 213). Strict- compliance of the same should be ensured.
Following three unsafe acts are strictly forbidden while handling
explosives:
1. The use or possession of intoxicants on or around the- job

2. Horse play or practical jokes
3. Smoking or use of open lights
6.1.2 Blasting records
Following two records have to be maintained in 'all quarries while

handling explosives :
A A blasting record for each blast indicating

- date & time of blast
- number of holes
- type of explosive used
- amount of charge per hole &
- firing pattern & sequence
B An inventory of all explosives received, placed in, removed from &

returned to storage magazines maintained current at all times.
Only licensed blasters shall be allowed to handle explosives.
6.1.3 Transportation:
• Explosives should not be carried in the same vehicle with detonators

unless the detonators are carried in a separate approved container.
• The vehicle should be equipped with a non-sparking metal or wooden

floor; the sides should be high enough to prevent the explosives from
falling off or it should be equipped with a closed body. If it is an open
Civil Work 1
body truck, a fire & waterproof tarpaulin shall be used to cover the
explosives.
• Two fire extinguishers must be provided in the vehicle.
• Congested traffic should be avoided while transporting explosives.

Unnecessary parkings at hotels, garages, filling stations etc, should be
avoided.
• Unauthorised persons or ' flammable & corrosive substances ’ shall not

be allowed in the truck carrying explosives.
• Smoking is not allowed in & around the vehicle carrying explosives.
6.1.4 Storage
• Explosives should be stored only in approved storage magazines

however small the quantity it shall be.
• While taking explosives for actual usage, it shall not be placed near
sources of heat or water.
• Smoking or possessing matches, etc. near the magazine is prohibited.
• Manufacturer should be consulted, if nitro glycerine from deteriorated

explosives has leaked onto the floor of the magazine. The floor should
be de-sensitized with an agent approved for that purpose by the
manufacturer.
• Leaves, grass, bush or debris shall not be allowed to accumulate

within 25 feet of an explosive magazine.
• Detonators should NEVER be stored in the same magazine with any

other explosives.
• Barrication of the storage area.
6.1.5 Using explosives:
• Explosive cases should not be opened using metallic tools.
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• Replace the cover of the case after the required quantity of explosive
is taken out.
• Smoking or other sources of fire are prohibited within a radius of 100

feet from the place where explosives are being handled or stored.
• Only fuse and nothing else shall be inserted in the open end of the
blasting cap.
• Explosive caps or fuses 'shall not be carried in the pockets of clothing,

etc.
• Children or unauthorised persons are totally prohibited in the blasting

area.
• Deteriorated or damaged explosive caps and other accessories shall

not be used and these shall be returned to the manufacturer.
• Quantity of the charge to be used must be well calculated and be safe

enough to prevent any damage to nearby structures due to shock &
vibration resulting from the explosion. The charge can be covered
with blasting mats, used conveyor belts or sand bags to prevent
splinters flying off especially in running plants.
6.1.6 Drilling & loading
• Before drilling is started, possible presence of unfired explosives

should be carefully checked. Never drill in the butts of old holes.
• Before loading, the condition of the holes should be checked either

with wooden tamping pole or measuring tape and not with hot broken
drill bit, etc.
• No. holes should be loaded except those that are to be fired in the
next round of blasting. Holes loaded during one shift should be fired
on the same shift.
• To avoid misfires, the detonator should be completely inserted length
wise in the cartridge, fastened in such a manner that it cannot be
pulled out accidentally.
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• Cap crimpers of proper design should be used for crimping blasting

caps onto fuse - not with ones teeth or a knife.
• The diameter of hole drilled should be at least 3 mm more than the

Diameter of the cartridge.
• Blasting should be carried out only during lean hours - say during
lunch time, night hours, etc.
6.1.7 Tamping
• Dynamite should not be normally removed from the cartridge, but if

this is done, loose dynamite should not be tamped.
• Only wooden tamping tool should be used; if metallic parts are used,
they should be of non-sparking type. Primer should never be tamped.
• Care should be exercised to avoid injuring fuse, detonating fuss. or

cap wires during tamping.
6.1.7 Warning signal
A standard warning signal and an all clear signal should be used before &
after firing and inspection. All personnel working in the area and nearby
area should be made aware of this established warning procedures.
At the same time competent persons equipped with red flags should be
posted at all possible approaches to the blasting area to stop traffic and
by passers from entering the danger zone.
6.1.8 Firing
In electrical firing following safe practices are recommended to avoid any

trouble.
• All electrical connections should be good & rigid.
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• The blasting machine should be in good order and of sufficient

capacity to fire all the electric blasting caps connected in the circuit. It
may be tested with a rheostat.
• Generator type blasting machine shall be operated few. times before

making the connections to prepare it for the maximum generation of
current. This type of blasting machine should be operated with
maximum force.
• Electric detonators or delay electric detonators of different

manufacturers should not be used in the same blast.
• The resistance of the circuit should be measured with a Blasting

Galvanometer before attempting to fire.
• Radio, television and radar transmitters create fields of electrical enery

which can detonate electric caps. Hence following minimum distance
must be maintained between the transmitters & electric blasting caps.
Transmitter power (watts) Min.distance(feet)
5 - 25 100
25 - 50 150
50 - 100 220
100 - 250 350
250 - 500 450
500 - 1000 650
1000 - 2500 1000
2500 - 5000 1500
5000 - 10000 2200
10000 - 25000 3500
25000 - 50000 5000
50000 - 100000 7000
For FM Mobile Transmitters
1 - 10 5
10 - 30 10
30 - 60 15
60 - 250 30
Civil Work 5
6.1.9 Misfires:
There is no absolute safe method for handling misfires. But misfires can
be prevented,
i by proper use of high-grade blasting supplies.

ii by testing each electric cap with a blasting galvanometer before
loading or
iii by testing the complete circuit before firing the blast.
However, if a misfire does occur, it should be handled very carefully, only

by experienced persons.
The safest way to dispose of a misfire is to re shoot it, if throw of rock

can be tolerated. When the trouble is caused by faulty connections and if
the leg wires are accessible, test the blasting cap with the galvanometer
and try to blast it in the usual manner after giving connections properly.
If the shot fails again, or if the wires are in-accessible, or if caps and
fuses are being used, try to Shoot the hole with a fresh primer. If this
also fails, the stemming should be removed carefully, a new primer
inserted and then fired.
Unused, spilled or deteriorated explosives should not be abandoned. It

should be preserved and disposed only by competent and experienced
persons. Wood, paper or fibre used in packing explosives should be
burned only in an isolated outdoor location. After the burning has
started, no person shall be allowed within 100 feet of the place of
burning.
Civil Work 6
Construction Blasting Inspection
Company Name: ______________________ Jobsite

Address:________________
Site Engineer: _______________________ Date/Time: ________ _________
SSO: _________________________
Yes No NA
1. Contractor qualifications and credentials

checked?
2. Explosive inventory completed and accounted
for at all times?
3. Stray electrical currents checked?
4. Blasting mats used when required?
5. All signs, warning signals, and protective
equipment in-place?
6. Non-essentials removed from area?
7. Radio transmissions limited?
8. Procedures for handling misfires in-place?
9. Explosives properly stored?
10. Is black powder prohibited?
11. Experienced and trained personnel handling
explosives?
12. Detonators tested before each shot?
13. Area inspection after each shot?
14. Proper disposal of wrappings, waste, and scrap?
15. Operations suspended during electrical storms
or when lightning is within 10 miles?
16. Explosives and related materials properly
stored?
17. All blasting operations conducted between sun-
up and sundown?
6.2 Excavation:
To prevent injury and property damage during excavation work,

make adequate` protective measures part of the job. Study pre-
excavation condition, such as superimposed loads, soil structure,
and hydrostatic pressure. From such a study, it is possible to
evaluate changes that might occur, to prepare for situations that
might develop, and to plan the job ahead. Excavation permits
should be used to ensure that all the necessary precautions are
taken to protect employees.
Underground Utilities
A major hazard in urban or built-up areas is the presence of

underground facilities, such as utility lines (water, electric, gas, or
telephone), tanks, process piping, and sewers. If this equipment is
dug into, undercut or damaged in any way, there may be injury or
death to workers, interruption of service, contamination of water,
disruption of processes and expensive delays. Many states have a
“one-call” system for locating buried lines. In one call all utilities
can be identified and all underground utilities will be marked.
Before starting operations, consult the company or plant engineer,

the utility companies, engineers, and the city’s or town’s engineers.
The location of various facilities and their approximate depth below
ground must be determined and marked by stake in the ground or
by marking on the floor.
Electronic locators can be especially helpful where an excavation

would cross numerous buried obstacles. If the facilities are to be
left in place, they must be protected against damage and
sometimes also against freezing.
Indicate the contents of buried tanks and piping on the location

markings. If the contents are flammable or toxic, have proper
protective equipment readily available in case of rupture. Also
indicate the bottom depth of tank.
Do the allow any shovel, dragline or other digging machine to
Civil Work 7
excavate close to underground facilities that must be left in place.

Establish a depth limit for digging machines, and complete the
excavation by hand digging. If personnel are working in a trench
deeper than 5-ft (1.5 m), provide adequate bracing and shoring or
have the trench slope. When hand excavation is being done, warn
workers about driving picks, paving breakers, or other powered
tools through buried facilities.
Barricades at Excavation Sites
Place excavated material at least 24-in. (0.6 m) from the edge of

the excavation unless toeboards or other effective barricades have
been installed to prevent fallback. Tarpaulins, sheeted barricades,
or low built-up board barricades can be used to confine the
excavated material to the immediate are under construction. Do not
permit excavated material to accumulate in work areas or aisles;
have them trucked or otherwise removed from the building.
Barricade excavations to prevent employees and others from falling

into them. When an excavation must remain open for the duration
of the construction work, barricades, fences, horses, and warning
signs are necessary. In some cases watchers and flaggers may be
needed. Guard the work area at night with flares, lanterns or
flashing lights. (See NSC Industrial Data Sheet 482, General
Excavation).
Guard the sides of all excavations in which employees are exposed

to danger from moving ground with a shoring system, sloping of
the ground, or other equivalent means. The minimum slope in any
soil, with the exception of solid rock, should be no less than three-
fourths horizontal to one vertical.
Base shoring, sloping and supporting systems (bracing, shoring,

cribbing etc.) on careful evaluation of factors such as (1) depth of
cut; (2) possible variation in water content of the material while the
excavation is open; (3) anticipated changes in materials from
exposure to air, sun, water or freezing (4) loading imposed by
structures, equipment, overlaying material, or stored material; (5)
and vibration from equipment, blasting, or traffic.
Civil Work 8
Have a competent person approve the excavation safeguards and

inspect shoring, sloping, and supporting systems daily and after
every rainstorm or other hazard increasing occurrence. Increase
protection against slides and cave-ins, if necessary. If evidence of
possible cave-ins or slides is apparent, all work in the excavation
should cease until the necessary precautions have been taken to
safeguard the employees
Except in hard rock, excavations below the level of the base of

footing of any foundation or retaining wall should not be permitted
unless the wall is underpinned and all other precautions taken to
ensure the stability of the adjacent walls. If the stability of
adjoining buildings or walls is endangered by excavations, provide
shoring bracing, or underpinning designed by a qualified person.
Have such shoring, bracing or underpinning inspected daily or more
often, as conditions warrant. Where it is necessary to undercut the
side of an excavation, safely support overhanging material.
Groundwater should be controlled. Freezing pumping, drainage and

similar control measures should be planned and directed by a
competent engineer. Consider the existing moisture balances in
surrounding soils and the effects on foundations and structures if it
is disturbed. When continuous operation of groundwater-control
equipment is necessary, provide an emergency power source. Use
diversion ditches, dikes, or other means (1) to prevent surface
water from entering an excavation and (2) to provide good
drainage of the area adjacent to an excavation.
Store and retain excavated material at least 2-ft. (61 m) from the
edge of the excavation to prevent excessive loading on the face of
the excavation. Remove boulders. Stumps or other materials that
may slide or roll into the excavation.
Provide walkways or bridges with guardrails where people or

equipment are required or permitted to cross over excavations.
Where personnel are required to enter excavations or ramps over
4-ft (1.2 m) in depth, provide sufficient stair, ladders or ramps.
Locate them so as not to require more than 25-ft (7.6 m) of lateral
travel. When access to excavations more than 20-ft (6.1 m) in
depth is required, provide ramps, stairs, or mechanical personnel
Civil Work 9
hoists. Ladders used as accessways should extend from the bottom

of the trench to not less than 3-ft (91 cm) above the surface.
Provide at least two means of exit for personnel working in
excavations. Where the width of the excavation exceeds 100-ft (30
m), provide two or more means of exit on each side of the
excavation.
When mobile equipment is used or allowed next to excavations,

install substantial stop logs or barricades. Operators of excavating
or hoisting equipment should not be allowed to raise, lower, or
swing loads over personnel in the excavation unless those
personnel have substantial overhead protection.
In locations where oxygen deficiency or gaseous conditions are

known or suspected, test the air in the excavation prior to the start
of each shift, or more often if directed by the designated authority.
A log of all test results should be maintained at the work site. If air
is not within specification, ventilation may have to be provided to
improve the condition. Test until air is safe. A confined space entry
procedure should be mandatory in excavations with oxygen
deficiencies or gase0ous conditions. Where such conditions are
suspected or are likely to develop in an excavation, have readily
available emergency rescue equipment such as breathing
apparatus, safety harness and line and emergency medical
supplies.
Trench Excavation
Trenches more than 5-ft (1.5 m ) deep should be shore, laid back
to a stable slope, or provided with other equivalent protection
where employees may be exposed to moving ground or cave-ins
as per OSHA regulations. Trenches less that 5-ft (1.5 m) deep also
should be protected when studies show hazardous ground
movement may be expected. Bracing or shoring of trenches should
progress with the excavation.
Portable trench boxes, sliding trench boxes, or shields should be

designed, constructed, and maintained to provide protection equal
to or greater than the sheathing and shoring be in true horizontal
position, secured to prevent sliding falling or kick-outs.
Civil Work 10
Back filling and removal of trench supports should progress

together from the bottom of the trench. Release jacks or braces
slowly. In unstable soil, use ropes to pull out the jacks or braces
from above, after personnel have cleared the trench.
In hand-excavated trenches, spike or bolt wooden clears to join the

ends of braces to stringers. This will prevent the braces from being
knocked out of place.
ln a long machine excavated trench a sliding trench shield may be
used instead of shoring. Sliding trench shields generally are
custom made to size for a specific job. They must be designed and
fabricated strong enough to withstand the pressures that will be
encountered. Metal, portable hydraulic shoring systems are also
available.
Civil Work 11
6.3 Piling :
Piling work is an integral part of any construction activity. If this

activity is not carefully prepared and executed, it can result in
delay as well as causing serious accidents. The Building and Other
Construction Workers ( Regulation of Employment and Conditions
of Service ) Rules, 1998 ( Rules 214 to 222 ) give detailed
statutory requirements to be complied with while doing the piling
work. It is advisable to adhere to certain basic safety measures
which are given below:
6.3.1 General precautions:
There are certain hazards, which are common to all types of piling,
and the following precautions are necessary.
1. Piling machine operators should be over 18 years of age and

properly trained;
2. Prior to piling, all underground services should be located and

made safe. A check should be made to ensure there are no
basements, underground water courses or ground conditions
which might cause hazards;
3. There should be a firm level base for the crane, or crane mats
provided;
4. When working on piling operations the worker should wear a

safety helmet and ear and eye protection where necessary.
5. All cranes, lifting appliances and lifting gear must have

appropriate certificates of testing and thorough examination,
and should be large enough for the job;
6. Particular attention should be paid to the risk of damage to

lifting gear from sharp edges;
7. Cranes used for raising or lowering workers must be fitted

with a dead man's handle and lowering should be done under
Civil Work 12
power; the worker should be carried in properly constructed

cages which cannot spin or tip;
8. Piling contractors should be asked to provide a written

method statement setting out the precautions relevant to the
type of piling they are to employ;
9. Induction training and information for the supervisor or

operative should be given and specifically related to the
method statement.
10. Workers should be encouraged to use Protective equipment

at all times when engaged in piling work,
6.3.2 Bored Piles:
Workers may need to enter a bore hole for inspection or for

clearing out in undercuts, and there are certain precautions, which
must be taken prior to such entry:
1. The bore hole should be at least 75 cm in diameter
2. The bore hole should be treated as a confined space and the

precautions which are advised elsewhere to ensure a
satisfactory atmosphere must be closely followed
3. Waste material from the bore hole should be kept clear of

the bore hole
4. Descent into a bore hole should be in properly designed

skips, chains or cages fitted with an anti-spin device. The
power source of the lifting-appliance should be kept
running throughout the time someone is underground
5. While the workers are working down a bore hole they must
wear a safety harness
6. All workers concerned must be trained and competent in

rescue from deep bore holes, and emergency rescue drills
should be carried out at regular intervals
Civil Work 13
7. A banks’man who can see you in the bore hole should be

present at all times
8. There must be adequate lighting at safe reduced voltage

and a means of communication from the bore hole.
9. Wherever possible, the need for workers to enter pile bore

holes should be avoided by the use of television cameras
and other techniques for remote inspection.
Civil Work 14
6. 4. Safety in working at Height
Several factors and serious accidents are caused yearly to

persons engaged in working at height such as building
construction where men have to go at heights & unless adequate
safety precautions are taken serious accidents can happen.
Investigations reveal that these accidents are caused by
improvised & make shit arrangements instead of providing proper
means of access.
6.4.1. Ramps & Runs
At the beginning of construction excavations are made to provide

proper foundations. As the depth increases the means of access
to the bottom will be through ramps & runs and to cross the
cuttings, gangways are to be provided.
The Ramps and Runways should be constructed and maintained
in such a way to comply with the provisions under rules 82 to 85
of The Building and other Construction Workers (Regulation of
Employment and Condition of Service) Central Rules, 1998.
The slope to the ramps & runs should be as far as possible,

max.15° to horizontal i.e. one in four and the total rise of a
continuous ramp does not exceed 3.7 meters, unless broken by
horizontal landing of at least 1.2 meters in length or as provided
in relevant standards / codes.
Cleats not more than 40 cm apart should be provided on ramps

with steep slopes. The width should be adequate for traffic. Toe
boards should be provided where ramps extend over a workplace
or passage. The open sides should be protected by railings as
required.
When the construction is started at some stage or other the

gangways or any other means or access should have to be
provided to reach higher levels.
At the top level where the work is to be undertaken, there are

certain precautions to be taken.
Civil Work 15
• Unprotected floors situated at a height and openings, pits

etc. in platforms should be protected by railings and toe
boards or otherwise guarded suitably.
• Toe board should not be less than 15 cm.
• There should also be an intermediate rail between floor and
top rail.
6. 4. 2. Ladders
Ladders should conform to the provisions given under Rules 172

to 174 of The Building and other Construction Workers
(Regulation of Employment and Condition of Service ) Central
Rules, 1998.
Ladders may be classified under two broad categories – Portable

and Fixed.
• Since the portable ladder is a hazardous piece of equipment

every effort should be made to replace it with fixed ladders
and scaffolds. It not only prevents the accident but also
saves time for carrying ladder from one place to other.
However we may have to resort to portable ladders for work
to be carried out at height for short period.
Single Ladders
These are as single unit and intended to be used as such. The rungs are
generally round or horizontal in cross section.
Some ladders are provided with flat plates in which case they are called
stepladders. B.I.S.4435: 1967 specifies that the treads should be
horizontal, when the ladder is inclined at an angle 650 – 750 to horizontal.
Where ladders can not be placed directly then retaining hooks or devices
should be provided on top of the ladder.
Some of the dos and don’ts while using single ladder are given in
annexure-1.
Civil Work 16
Working on Roof :
Some accidents happened due to fall of persons working on roof. Fall

through fragile roof sheeting, loss of balance due to steep slope of the
roof and insufficient care while working at the edge of the roof constitute
the principle causes for these accidents which could be prevented by the
safety measure given below.
Roofs covered with asbestos sheets, roof light covering glass or perspex
can break under the weight of the person and working along perlins can
not be relied upon.
Best way to prevent fall is to use specially designed roof ladders.
They should be atleast 38cm wide should have cross battens of at least
3.2cm thick and with a gap between them not more than 38cm.
The ladder should be of sufficient to withstand the weight of the person

and the material he carries, when spanning across the points of support
on the roof.
It is not safe to fix the headboard or anchor board to the ladder by nails
alone. Designs of wooden and metal ladders are given in annexure-2.
A common mistake in securing the roof ladder is to allow the anchor

board or other anchorage to bare on the ridge capping. The capping may
break off if it is off brittle material or the anchorage may slip away. The
right method is to have the anchorage to bear on the opposite slope or to
be secured by other means such as rope.
For curved roofs, special ladders to suit the shape of the roof will have to
be designed.
To ensure safe working at least two roof ladders are to be provided.
Safety belts should also be used as additional precaution.
The permit to work system given in the annexure (under the control of
respective person) can help to ensure that persons are not allowed to
work on roof without adhering to the above safety precautions. (a model
work permit is given in annexure-3).
Civil Work 17
Warning notices must be displayed at all approaches to the fragile roof.
Falls from the side of the roof can be prevented by providing a strong
barrier at the edges of the roof.
6. 4. 3. Scaffoldings :
Whenever construction or maintenance work above floor level

can not be safely carried out from the ground, from any part of
the building or permanent structure from a ladder or any other
means of support, suitable scaffold should be provided. The
scaffold serves 2 purposes.
One is to provide convenient platform to perform work at

heights.
The other is to provide safe means of access to all places where

any person is required to work at any time.
Accidents at scaffolds are generally caused either due to direct

collapse of the scaffold or as a result of person or material falling
of the scaffold.
Great care is therefore necessary in erection, use and

dismantling of scaffolds. These should conform to the provisions
of the Rules 188 to 205 of “The Building and other
Construction Workers ( Regulation of Employment and
Condition of Service ) Central Rules, 1998”.
General requirements are:
1. All scaffolds should be of suitable design, sound construction with

material of sufficient strength. The erections, alterations and
dismantling of scaffold should be done under the supervision of
competent person.
2. Scaffold should be designed to carry at least 4 times the anticipated

load. They should be securely supported or suspended and should
Civil Work 18
wherever necessary, be sufficiently and properly strutted or braced to

ensure stability.
3. Safe means of access should be provided t all scaffold platforms.

Failure to provide such access has caused many serious accidents. The
safe means of access may be by ladders (portable or fixed), ramps,
runways, gangways or stairways.
It is recommended that portable ladders should not be used as a

means of access if height of the platform of scaffold exceeds 3.75 m.
Stairways are the fastest and the most efficient. Ramps and runways
are also safer than ladders, but can not be used where there is
appreciable difference of the levels to be connected. The use of cross
braces or framework of the scaffolds as means of access should not be
encouraged.
4. Overhead protection: In case work is in progress at higher level than

that of scaffold, then suitable protection should be provided so as to
prevent falling tools etc. from the higher level informing the workers
working on the scaffold.
5. Protection under scaffold: When persons are required to work or pass

under scaffold, it is necessary to provide a screen or canopy over the
area. Such protection should extend at least 30 cm outside the
scaffold proper in order to catch any material falling from the edges of
scaffold. Screening with 13 mm wire mesh of 18-gauge wire is
satisfactory for ordinary purpose. Instead of wire mesh planking with
15-mm planks or steel corrugated sheeting can also be used.
6. Width of working platform:

Following minimum widths are recommended as a general rule as per
BIS 4014 (part II) – 1967.
! If a platform is used
as a footing only .......... 700 mm
for the deposit of material .......... 900 mm
for support of any platform .........1100 mm
for dressing stone or bricks .........1300 mm
for purposes stated in (3) & (4) above
..........1500 mm
! Extended at least 60 mm beyond the end of the support.
Civil Work 19
6. 4. 3. 1. Railings and Toe boards
The railings should consist of a top rail at a height not less than 90 cm
(max. 120 cm) above the platform and an intermediate rail halfway
between the top rail and the platform. The railings should be strong
enough to withstand a load of 90 kg applied in any direction on the top of
the rail.
It is also essential to provide toe boards at the edges of the platform.

Height 150cms.
Steel components of tubular scaffolds should conform to the

requirements laid down in BSI 2750-1964.
The scaffolds should be periodically inspected.
Other General Safety Practices
1. Competent person should inspect scaffolds after erection and before

use.
2. A common cause of failure in a scaffold is the removal of structural
parts while in use. This should be strictly prohibited.
3. Periodic treatment against deterioration due to weather conditions
should be carried out.
4. There should be sufficient gap between hoisting equipment and
scaffold to prevent material from hoist getting entangled with scaffold.
5. People should not be allowed to work in bad weather condition such as
storm.
6. Some of the scaffold sketches are given in annexure-4.
6. 4. 4 Safety Belts
There are many situations where it may not be practicable to provide all
the normal measures to protect persons falling from heights. In such
cases, the persons should wear safety belts secured suitably through a
line to a proper anchorage.
Civil Work 20
There are four common types of safety belts namely, Pole safety belt,
General purpose safety belt, General purpose safety belt with remote
anchorage and Harness (Man hoisting) type safety belt.
The material of the safety belt which should be chosen (leather and
webbing of natural and man-made fibers) according to the job
requirements.
Lifelines should be secured to permit as little slack as possible.
In case of obstruction for free fall, shock absorbers should be provided

for the lifeline.
PP or nylon rope of 12 mm diameter are suitable for use as lifeline.
Steel cables are not suitable for use as lifeline in case where a free fall is
possible, unless shock absorber is provided. The belts should be
maintained properly with periodic inspections.
Annexure-5 gives important standards, convention pertaining to this

chapter.
Civil Work 21
Annexure 1 (Ladders)
a) While carrying ladder, the leading end should be at least 2 meters

above ground. Long ladders should be carried by 2 persons.
b) Ladder should be placed on firm base and on a level ground.
c) Ladder should be placed against a firm support for the stiles to rest on
it securely. One ladder should be fixed firmly either through lashing or
hooks at the top.
d) The slope of the ladder to wall / support should not be more than 75°
to the floor (i.e. 1 foot gap at the base to wall and 4 feet from the top
resting place to the ground.
e) Non slipping devices should be put to the bottom ends of ladder when
sued on slippery flooring.
f) Persons ascending / descending the ladder should always face the

ladder.
g) Ladder should not be misused and should be maintained properly.
Civil Work 22
Larson & Toubro Limited
E & C Division
Safety at Working at Height Check-List
Name of Job site: -
SI. Description Observation Remarks
No. Yes/No
1. All the workers have been explained safe
work method?
2. An established communication system have
been established and explained to the
workers.
3 Adequate illumination has been ensured
4 Work area inspected prior to start the work
5. Area below the work place
barricaded,especially below hot work
6. Workers provided with bags/box to carry
bolts, nuts and hand tools.
7. Arrangement for fastening hand tools made.
8. All work platforms ensured to be of
adequate strength and ergonomically
suitable
9. Fabricated makeshift arrangements are
checked for quality and type of material
welding, anchoring etc.
10. Work at more than one elevation at the
same segment is restricted.
ACCESS / EGRESS
1. Walkways provided with handrail, mid-rail &
toe guard?
2. All checkered plates, gratings properly
welded / bolted?
3. Are ladders inspected and whether they are
maintained in good condition?
4. Are ladder spliced?
5. Are ladders properly secured to prevent
slipping, sliding or falling?
6. Do side-rails extend 36” above top landing?
7. Are built up ladders constructed of sound
materials?
8. Are rungs and cleats not over 12” on
center?
9. Metal ladders not used around electrical
hazards.
10. Proper maintenance and storage
11. Ladders placed at right slop
12. Ladders, staircases welded / bolted
properly.
13. Any obstruction in the stairs
14. Are landing provided with handrails, knee
rails, toe boards etc.
15. Whether ramp is provided with proper slope
16. Proper hand rail/ guards provided in ramps.
House – Keeping
1. Walk ways,aisles & all overhead
workplaces cleared of loose material
2. Flammable material,if any, are cleared
3. All deshuttering material are removed
after deshuttering is done
4. Platforms and walkways free from
oil/grease or other slippery material
5. Collected scrap are brought down or
lowered down and not dropped from
height
PPE and Safety Devices
1 Use of safety helmets,safety belts
ensured for all workers
2. Anchoring points provided at all places
of work
3. Common life line provided where ever
linear movement at height is required
4. Safety nets are in use wherever
required
5. Proper fall arrest system is deployed
at critical work places
6. Crawler boards/Safety system for
work on fragile roof are used
6.5 Demolition of Structures
Plant personnel should do only minor demolition. Employ specialists

in the field if structures to be removed look as though they will
present a problem. Wrecking specialists are familiar with the
procedures and precautions necessary to do the wo0rk safely.
They know how to protect the public and adjacent property, and
they know the applicable federal, state or provincial, and municipal
codes and regulations.
Following are minor demolition work:
• Make provision to keep the public and unauthorized plant employees

at least 15-ft (5 M) away from the structure.
• Have a competent person make an engineering survey of the
structure. Determine the condition of the framing, floor, and walls, and
check for any unanticipated conditions. Check for hazardous
chemicals, gases, explosives, flammable materials, asbestos,
hazardous waste, electrical circuits that may be engaged, etc.
• Disconnect utility services (gas, steam, and electricity) outside the
building. Notify the utility companies in advance. Maintain water lines
as long as possible. Maintain or install a temporary water source for
fire protection and for wetting down the site to reduce dust.
• Remove all glass doors and windows through out the structure.
• Strip off lath and plaster to eliminate excessive dust during succeeding
work.
• Remove chimneys and extensions of walls above the roof, down to
roof level, while working from the roof.
• Remove the roof.
• Remove walls by picking them apart, using either machine or hand
tools. Work from scaffolds supported independently outside the walls.
• Remove all debris promptly, through chutes or internal holes. To
minimize production of dust assign persons to wet down the debris.
Post signs that warn of falling materials.
• Avoid subjecting walls to lateral pressure from stored materials or to
lateral impact from falling material.
• Barricade any area where material is being dumped, and place
barricades where necessary to protect workers from flying pieces.
• Prohibit employees from working below others.
Civil Work 23
• Remove asbestos in an approved manner.

• Require safety hats, goggles, foot protection, respirators, and gloves
as needed for all workers. (See Chapter 14, Personal Protection
Equipment.)
• Develop necessary safety procedures for handling hazardous materials
and provide training for employees.
• Avoid exceeding the allowable floor loads for the storage of waste and
debris.
• Make continuing inspections to detect hazards resulting from the
demolition operation.
Sometimes the conventional methods for altering or removing concrete

installations are unfeasible or undesirable. In such cases, use (1) “powder
cutting,” a process that substitute penetration by intense heat for
concussion breakage, or (2) explosive.
6.6 Carpentry Workshop
6.6.1 Plant Layout :
The following general principles should be followed while siting

the machinery:
• Provide a minimum of 1m backspace for the machine

operator.
• Ensure that the timber used does not interfere with
operations on adjacent machines.
• Provide clear passage around the machine.
• Keep the materials properly stacked and away from
machines.
6.6.2 Housekeeping :
• The space around every wood working machine shall be free

from obstruction.
• The floor of the workshop shall be cemented and maintained
in good condition. It shall not be allowed to become slippery
and as far as possible shall be kept free from chips or other
loose material.
Civil Work 24
• A cordoned area shall be demarcated to dump the wood

shavings, dust and pieces.
6.6.3 Machinery :
• Dangerous parts of the machinery shall be adequately

guarded.
• Push stick should be used and should be kept near the
machine.
• Stopping and starting devices shall be located within the
reach of the operator.
6.6.4 Operator :
The Carpentry in-charge should nominate the required number of

operators who will be authorised to work on the wood-working
machines. Their names must be displayed on a board near the
machine with a statement saying no other is authorised to work
on the machine.
The designated operator shall be employed after he has been

sufficiently trained to work on the wood working machinery and
he should be adequately instructed as to the inherent dangers
involved in the operation.
6.6.5 Personnel Protective Equipment (PPE) :
Suitable personal protective equipment should be used by the

operator while working on the machinery. After use these
equipment should be stored near the machine.
6.6.6 Lighting :
• Lighting must be adequate and suitable for the work being

carried out.
• Lighting should be provided in such a way to prevent glare
and direct lighting on the work.
The illustrations given in the annexes provide proper method of

guarding and working on wood working machines.
Civil Work 25
ANNEXURE 1
SUMMARY OF SAFETY RULES FOR VARIOUS WOODWORKING

TOOLS
Every operator should be trained in the safety rules covered in this

chapter. As a summary, safety rules that demand close attention are
listed below. Be sure the operator checks the manufacturer's manual,
understands the requirements, and follows the recommended procedures.
TABLE SAW
JOINTER/PLANER
• Feed with the body to side of stock
• Blade height • Depth of cut
• Splitter and anti kickback fingers for • Length of stock
ripping • Sharp cutters
• Stock firm to fence • No hands over cutters
• Remove rip fence for crosscuts • Push stick for small stock
• Blade guards • Guard
CIRCULAR SAW WOOD SHAPER
• Blade guards • Clamping work piece

• Binding • Use correct guard
• Blade-correct type • Feed into knives-don't back
• Blade-tight on the arbor off
• Firm support for work • No feeding between fence
• No obstructions and cutters
• Begin cut with motor at manufacturer's • Collar and starting pin work
recommended speed for materials being for irregular work-stock
cut of sufficient weight
• Hand and finger position • Fence opening only enough to clear cutters
Use stock as guard by shaping the
RADIAL ARM SAW underside of stock
Spindle nut tight
• Rip sawing-direction of feed (cut) and anti Shape only pieces 10 in. or longer
kickback fingers Proper types of cutters
• Blade guards
• Pull for cross cuts SANDER
• End plates on track-arm tight
• Clamp handles tight • Keep hand from abrasive surface
• Material tight to fence • Ventilation
• Belt or disk condition
Return cutter to rear of track • Sand on downward side of disk
Hand and finger position
LATHE
BAND SAW
• Stock without defects, glued joints dry
• Feed with body to side of stock • Power off when changing speeds on belt
• Guard height 1/8-in. clearance of material lathes
• Tension and type of blade • Tool rest close to stock
• Release cuts before long curves • Hold tools firmly in both hands
• Stop machine to remove scrap or pull out • Remove tool rest when sanding or polishing
incomplete cut
• Flat stock
• Push stick for small parts
Civil Work 26
When the width of the rip is 6 in. or wider,

uses your right hand to feed the workpiece When the width of the rip is less than 2 in., the
until it is clear of the table. Only use the left push stick cannot be used because the guard
hand to guide the workpiece-do not feed the will interfere. Use the auxiliary fence-work
workpiece with the left hand. support and push block. Use two C clamps to
attach the auxiliary fence-work support to the
rip fence.
Feed the workpiece by hand along the

auxiliary fence until the end is about 1 in.
beyond the front edge of the table. Continue
to feed using the push block. Hold the
workpiece in position and install the push When the width of rip is 2 in. to 6 in., use the
block by sliding it on top of the auxiliary push stick to feed
fence-work support (this might raise the the work.
guard).
Narrow strips thicker than the auxiliary fence-work support may enter the guard and strike the
baffle.Carefully raise the guard only enough to clear the workpiece. Use the push block to complete the cut.
Civil Work 27
A clear plastic shield has been formed into a guard for this band saw.
Note the difference between a hold down (left) and a push block (right). The push block has a piece of wood
acting as a Positive stop against the end of the workpiece; the hold down is flat on the bottom, Both are used to
keep the operator's thumbs and fingers away from the cutter head.
Civil Work 28
Close – up of a properly functioning splitter (Driving knife) and antikickback device

during a ripping operation.
Civil Work 29
6.7 Grinding Operation:
Introduction
The commonly used grinding m/c s in construction are the

portable grinding m/cs. The speed of the wheels ranges from
7000 rpm to 14000rpm or sometimes more than that. Even a
minor mishandling would lead to a serious mishap. Hence
grinding operation ought to be done by a trained operator
following the safety norms.
Grinding is a hazardous operation. The grinding wheel rotates at
a speed of more than 7000 rpm that cause a very serious injury
Grinding machines shape material by bringing it into contact with
a rotating abrasive wheel or disk. Grinding includes surface,
internal, external cylindrical and centerless operations, as well as
polishing, buffing, honing, and wire brushing. Portable machines
that use small, high-speed grinding wheels have been dealt
under Hand and Power Tools.
6.7.1 Grinding Machine Hazards
Hazards associated with grinding machines include the following:
• Failure to use eye protection in addition to the eye shield

mounted on the grinder.
• Incorrectly holding the work.
• Incorrectly adjusting or not using the work rest.
• Using the wrong type, a poorly maintained or in- balanced
wheeler disk.
• Ringing on the side of a wheel not designed for side grinding.
• Taking too heavy a cut.
• Applying work too quickly to a cold wheel or disk.
• Grinding too high above the wheel's centre.
• Failure to use wheel washers (blotters).
• Vibration and excessive speed that lead to bursting a wheel or
disk.
• Using bearing boxes with insufficient bearing surface.
• Using a spindle with incorrect diameter or with the threads
cut so the nut loosens as the spindle revolves.
Civil Work 30
• Installing flanges of the wrong size, with unequal diameters,

or with unrelleved censers.
• Incorrect wheel dressing.
• Contacting unguarded moving parts.
• Using controls that are out of the operator's normal reach.
• Using an abrasive blade instead of a grinder disk.
• Failure to run a wet wheel dry, without coolant, for a period of
time before turning off the machine.
• Using an untested, broken, or cracked grinding wheel.
• Reaching across or near the rotating grinding wheel to load,
unload, or adjust the machine during set-up.
6.7.3 Abrasive Disks and Wheels
An abrasive disk is made of bonded abrasive, with inserted nuts

or washers, projecting studs, or tapped plate holes on one side of
the disk. This side is mounted on the faceplate of a grinding
machine. Only the exposed flat side of an abrasive disk is
designed for grinding.
An abrasive wheel is made of bonded abrasive and is designed to

be mounted, either directly or with adapters, on the spindle or
arbor of a grinding machine. Only the periphery or
circumferences of many abrasive wheels are designed for
grinding.
6.7.3 Inspecting abrasive wheels:
Ring test :
When unpacking abrasive disks and wheels, inspect them for
damage from shipment and perform the "ring' test. This test can
be used for both light and heavy disks or wheels that are dry and
free of foreign material. To conduct the ring test, suspend a light
wheel from its hole on a small pin or the finger, and place a
heavy one vertically on a hard floor. Then gently tap the wheel
or disk with a light tool, such as a wooden screwdriver's handle.
A mallet may be used for heavy wheels or disks. Make the tap at
a point 45 degrees from the vertical center line and about 1 or 2
in. (2.5 or 5 cm) from the periphery. A wheel or disk in good
condition will give a clear, metallic ring when tapped. Wheels
Civil Work 31
and disks of various grades and sizes have different pitches. (ring
test to be done on receipt by the user.)
Visual Inspection on breakage, expiry dates designed rpm & wear
& tear of the wheel etc.
Daily inspection of grinding machines should include the points
shown in Figure.
Thoroughly investigate grinding wheel and disk failures,
preferably with the manufacturer's representative. This type of
investigation, along with immediate corrective action, greatly
reduces the possibility of recurrent failures.
6.7.4 Handling abrasive disks and wheels:
! Abrasive disks and wheels require careful handling.

! Do not drop or bump.
! Do not roll large disks and wheels on the floor.
! Transport disks and wheels too large or heavy to be carried
by hand
! By truck or other means that provide the correct support.
6.7.5 Storing abrasive disks and wheels: fifo method
Store abrasive disks and wheels in a dry area not subject to

extreme temperature changes, especially below-freezing
temperatures. Wet wheel might break or crack if stored below
32 F (0 C). Breakage of a wheel or disk can occur if it is taken
from a cold room and work is applied to it before it has warmed
up.
Store abrasive disks and wheels in racks in a central storage area

under the control of a specially trained person.
The length of time abrasive disks and wheels may be stored and
still be safe to use should be in accordance with manufacturers'
recommendations. Give the ring test to disks and wheels taken
out of long storage. Follow this by a check for recommended
speed, and a speed test on the machine on which it will be
mounted. Check the speed of all grinding wheels against the
spindle speed of the machine-some are designed only for low-
Civil Work 32
speed use. The grinding wheel must be rated at the same RPM
as the machine or more than the machine rpm. If it is not, the
wheel may explode and throw particles into the work area
causing serious at times fatal injuries.
Mounting wheels :
Mount all abrasive wheels between flanges. Exceptions to this

rule include mounted wheels, threaded wheels (plugs and cones),
plate-mounted wheels, and cylinder, cup, or segmental wheels
mounted in chucks.
Flanges should have a diameter not less than one-third of the

wheel's diameter. Flanges for the same wheel should be of the
same diameter and thickness, accurately turned to correct
dimensions, and in balance. The requirement for balance does
not apply to flanges made out of balance to counteract an
unbalanced wheel.
Key, screw, shrink, or press the inner or driving flange onto the
spindle. The bearing surface of the flange should run true with
the spindle. The outer flange's bore should easily slide onto the
spindle. (hand tightening , blotter paper)
Schedule flange inspections frequently. Remove from the spindle

a flange found to be sprung, not bearing evenly on the wheel, or
defective in any other way. Replace it with a flange that is in
good condition.
An incorrectly mounted abrasive wheel is the cause of much

wheel breakage. Since rotational forces and grinding heat cause
high stresses around the wheel's central hole, follow safety
regulations concerning size and design of the wheel.
Civil Work 33
GRINDER CHECKLIST
TYPE _____________ RPM ________
SIZE ______________ PERIPHERAL SPEED________
Item OK NOT OK
• WHEEL GUARD: securely fastened

Properly aligned
• GLASS SHIELD: clean
- unscored
- in place
• WORK REST: within 1/8 in. (3.2 mm) of wheel
securely clamped
• FRAME: securely mounted
no vibration
• WHEEL FACE: well-lighted
dressed evenly
• FLANGES: equal size
correct diameter (1/2 wheel diam.)
• SPEED: correct for wheel mounted
• GUARD FOR POWER BELT OR DRIVE:
in place
DATE _______ DEPARTMENT ________
INSPECTED BY _____________
Civil Work 34
6.7.7. Operating a Grinding Machine:
When starting a grinding machine, stand to one side away from

the grinding wheel. Allow at least one minute of warm-up time
before grinding with the wheel. Always use coolant when truing
the wheel or during normal grinding. Never allow coolant to flow
on a stationary grinding wheel; coolant might collect on one
portion of the wheel, causing an unbalanced condition. This
unbalanced condition can cause the wheel to disintegrate upon
restarting. ( the underlined portion stands good for fixed grinding
m/c not for portable one.)
While the machine is running, never remove a guard fastener or

guard. The guards are on the machine for the operator's safety;
if they are removed, serious injuries to the operator or others can
result.
Do not touch any moving part of the machine or the rotating
grinding wheel to determine its smoothness or condition.
Do not attempt to physically operate a machine that is in its
automatic mode.
Never alter or try to alter the machine, its wheel speed, or any of
its safety equipment at any time.
6.7.8 Safe Speeds :
Do not operate abrasive wheels and disks at speeds exceeding

those recommended by the manufacturer. In particular,
unmarked wheels of unusual shape, such as deep cups with thin
walls or backs with long drums, should be operated according to
the manufacturer's recommendations.
As the wheel wears down, the spindle's speed (rpm) sometimes

increased to maintain the surface speed (sfpm). When the wheel
is nearly worn down, the spindle is running at the highest rpm.
When the worn wheel is replaced, adjust the spindle's speed. It is
not possible and there is no need of adjustment of the spindle. If
the spindle's speed is not adjusted, the new wheel might break
because the surface speed exceeds manufacturer's
recommendations.
Civil Work 35
Grinding equipment for high-speed operation should be specially

designed. Give special attention to spindle strength, guards, and
flanges to eliminate mounting stresses. Such things as side-
grinding pressure and the wheel's shape, mat also be considered.
Proper maintenance and protective devices are also important for
safe high-speed operations. Obtain the manufacturer's approval
(instructions) for all high speed wheel and disc operations.
Civil Work 36
6.7.9 Work Rests :
Because work has become wedged between the work rest and
the wheel, many bench and floor-stand grinder wheels have
broken, thus causing serious injury. The work rest should be
substantially constructed and securely clamped not more than
1/8 in. (3.2 mm) from the wheel. Check the work rest's
position frequently. The work rest's height must be on the
horizontal centreline of the machine's spindle.
Never adjust the work rest while the wheel is in motion. The
work rest might slip and strike and break the wheel, or the
operator might catch a finger between the wheel and the work
rest. To prevent work from adding twisting and bending stress
to the wheel, operators should use guides to hold the work in
position when slot grinding or performing similar operations.
DRESSING ABRASIVE WHEELS
Abrasive wheels that are not true or not in balance will produce
poor work. They can damage the machine and injure the
operator. Keeping the wheels in good condition eliminates
these possibilities, decreases wheel wastage, and lengthens the
wheel's life.
To recondition a rutted or excessively rough wheel, often it is

necessary to dress it by removing a large area of the face.
Equip wheel-dressing tools with hood guards over the tops of
the cutters. They will protect the operator from particles flying
from the wheel or pieces of broken cutters. The operator of a
wheel dresser should use a rigid work rest set close to the
wheel. The operator should move the wheel dresser back and
forth across the wheel's face, while firmly holding the heel or
Lug-on the underside of the dresser's head-against the edge,
and not on top of the work rest.
Occasionally test wheels for balance, and rebalance them if
necessary. Wheels that are too worn, or too out of balance, to
be balanced by truing or dressing should be taken out of
service.
Civil Work 37
6.7.10 Surface Grinders and Internal Grinders:
Operating requirements for surface grinders and internal grinders

differ from those for other types of wheels. Insecurely clamped
work pieces and unenergised magnetic chucks are common
sources of injury to operators of surface grinders.
Under these conditions, work pieces can be thrown with

considerable force
If the operator takes too deep a Cut or too quickly traverses the
table or wheel, the wheel can overheat at the rim and crack.
Therefore, train operators, and supervise them to clamp work
tightly. They must always properly adjust and turn on a
magnetic chuck before applying the wheel. They must also
control the work's speed and depth.
Baffle plates on each end of a surface grinder are usually
standard equipment. They should also include some provision for
exhausting the grinding dust.
Internal grinders can often be guarded with an automatic
positioning hood. This kind of hood covers the grinding wheel
when it is in the retracted or idling position.
6.7.11 Grindstones:
When using grindstones, follow the manufacturer's suggested

running speeds and operating procedures. Never run stones of
unknown composition or manufacture at more than 2,500 sfpm
(12.5 m/s), and ordinarily not more than 2,000 sfpm (10 nets).
The size and weight of grindstones require a stand that is rigidly
constructed, heavy enough to hold the stone securely, and
mounted on a solid foundation to withstand vibration.
Since grindstones are run wet, take all possible precautions to

prevent slipping accidents near the stones. Use rough concrete
or other slip-resistant floor material in grindstone operating
areas.
Carefully inspect grindstones for cracks and other defects, as

soon as they arrive from the manufacturer. Store those not to
Civil Work 38
be used immediately in a dry, uniformly heated room, where they

will not be damaged.
Many grindstone failures result from faulty handling and incorrect

mounting. Do not leave grindstones partially submerged in
water. This practice causes an unbalanced stone that can break
when rotated. Do not use wooden wedges on power-driven
stones. Often, these wedges are too tightly driven or can
become wet and swell. In either case, cracks start in the corners
of a square center hole, radiate outward, and weaken the stone
causing ruptures to occur when operated at normal speeds.
After the stone has been centred, fill the central space about the
arbor with lead or cement. Use double thickness of leather or
rubber gaskets, rather than wood washers, wherever possible. If
wood washers are used between the flanges and the stone, the
washers should be '/2 to 1 in. (1.3 to 2.5 cm) thick and the
flanges should be clamped in place by heavy nuts.
To remove dust and wet spray or mist when dressing or

operating power-driven grindstones (either wet or dry), provide
an adequate exhaust system. Work rests should comply with the
same requirements as those for grinding wheels.
6.7.12 Polishing Wheels and Buffing Wheels :
Polishing wheels are either wood faced with leather or made of

stitched-together disks of canvas or similar material. A coat of
emery or other abrasive is glued to the periphery of the wheels.
Buffing wheels are made of disks of felt, linen, or canvas. The

periphery is given a coat of rouge, Tripoli, or other mild abrasive.
The softness of the wheel, built up of linen, canvas, felt, or

leather, is determined by the size of the flanges used-the larger
the flange, the harder the surface. When large flanges are used,
it often is necessary to soften the working surface of the built-up
wheels to conform to the contour of the object being polished. A
safe procedure for softening the working surface is to place the
wheel on the floor or other flat surface and pound the edges of
Civil Work 39
the wheel with a hammer or mallet. Do not place the wheel on

the spindle with a file or other object held against it. The file
could catch in the wheel and be thrown with such force that the
operator or nearby workers are injured.
6.7.13 Mounting :
Mount polishing wheels and buffing wheels on rigid and

substantially constructed stands that are heavy enough for the
wheels used. Mounting procedures for polishing wheels and
buffing wheels are the same as those for grinding wheels.
6.7.14 Safeguards :
Hood guards should be designed to prevent the operator's hands

or clothing from catching on protruding nuts or the ends of
spindles. If working conditions require a hood that does not give
the needed protection, then use a spanner wrench to install
smooth nuts over the spindle's ends. Never substitute a prick
punch and hammer for a spanner wrench. Exhaust hoods should
be designed to catch particles thrown off by the wheels when
working in a workshop.
Operators of polishing wheels and buffing wheels should not wear

gloves. A glove can catch and drag the operator’s hand against
the wheel. Operators should not attempt to hold a small piece
against the wheel with the bare hands. Small pieces being
polished or buffed can frequently be bed in a simple jig or fixture.
Some operators use a piece of an old linen or canvas wheel for
holding small pieces.
When applying rouge or tripoli to a revolving wheel, hold the side

of the cake lightly against the wheel's periphery. If a stick is
used, apply the side of the stick to the off side so, if thrown, it
will fly away from the wheel.
6.7.15 Wire Brush Wheels:
Wire brush wheels or, more commonly, scratch wheels are used
to remove burrs, scale, sand, and other materials. These wheels
Civil Work 40
are made of various kinds of protruding wires, with different

thickness.
The same machine set up and conditions that apply to polishing

and buffing wheels apply to wire brush wheels. Use flanges or
nuts to hold scratch wheels rigidly in place. Do not exceed the
speed recommended by the manufacturer. The hood on scratch
wheels should enclose the wheel as completely as the nature of
the work allows. The hood should also be adjustable so
protection will not lessen as the diameter of the wheel decreases.
The hood should also cover the exposed arbor ends. If not,
install a smooth nut on them. Adjust the work rest to about 1/8
in. (3 mm) from the wheel.
Personal protective equipment is especially important when

operating scratch wheels because the wires tend to break off.
Make it mandatory for operators to wear aprons made of leather,
heavy canvas, or other heavy material; leather gloves; face
shields; and goggles.
Civil Work 41
Grinding Wheel
Grinding Wheel
Undercut
necessary Wheel Blotter
for firm fit
Flange Recessed
Wheel
Spindle Wheel Spindle
Inner flange keyed screwed,

shrunk or pressed
Wheel easy
Blotter fit on flange
shoulders
Correct methods of mounting abrasive wheels with large

holes (left) and wheels with small holes (right)
Civil Work 42
A badly rutted or out – of – balance

grinding wheel should be taken out of
service and dressed
Top: with a properly adjusted work rest, the

operator can keep the hands away from the
wheel and still firmly hold the work in place.
Bottom: there should be a safe space of no

more than 1/8 in. (3.2 mm) between the tool
rest and the wheel.
Civil Work 43
6.8 Formwork & Falsework
The planning and design of formwork and falsework should be in

accord with provisions of the American Concrete Institute
Publication ACI 347-78, Recommended Practice for Concrete
formwork and ANSI A10.9 Safety Requirements for Concrete
Construction and Masonry Work.
All formwork, falsework, structural shoring and bracing should be

designed, erected, braced and maintained to safety support all
vertical and lateral loads that might be applied until such loads can
be supported by the structure. Drawings and plans shall be
available at the job site.
All shoring equipment shall be inspected prior to erection to

determine that it is as specified in the shoring layout. Any
equipment found to be damaged should not be used for shoring.
Erected shoring equipment shall be inspected immediately prior to,
during and immediately after the placement of concrete.
Immediately reinforce or reshore any shoring equipment found to
be damaged, displaced or weakened.
The sills for shoring should be sound, rigid and capable of carrying
the maximum intended load. All baseplates, shore heads,
extension devices, or adjustment screws should be in firm contact
with the footing sill and the form. Prohibit eccentric loads on shore
heads and similar parts, unless these parts have been specifically
designed for such loading.
When single post shores are used one on top of another (tiered),
1. The design of the shoring shall be prepared by a qualified

designer and the erected shoring inspected by an engineer
qualified in structural design.
2. The shores shall be vertically aligned.
3. The shores shall be spliced to prevent misalignment.
4. The shores shall be adequately braced in two mutually
perpendicular directions at the splice level.
5. Each tier shall also be diagonally braced in the same two
directions
Civil Work 44
6. Adjustment of single post shores to raise formwork shall not be

made after placement of concrete.
Remove and stockpile stripped forms and shoring promptly after

stripping. Protruding nails, wire ties and other form accessories not
needed for later work should be pulled, cut, or by other means taken out.
Supply employees with eye and or face protection when nailing into
concrete. Require employees to wear this personal protective equipment.
Provide reshoring to safety support slabs and beams after stripping. Also
provide reshoring when slabs and beams are subjected to superimposed
loads due to construction. When temporary storage of reinforcing rods,
material, or equipment on top of formwork is needed, strengthen these
areas to meet the intended loads.
Adequately reinforce steel for walls, piers, columns, and similar vertical
structures to prevent overturning or collapse. Do not load metal tubular
frames used for shoring beyond the safe working load recommended by
the manufacturer. Keep all locking devices on metal tubular frames and
braces in good working order. Coupling pins should align the frame or
panel legs. Pivoted cross braces should have their center pivot in place.
All components should be in a condition similar to when originally
manufactured.
Fasten devices for attaching the outside lateral bracing to the legs of the
metal tubular shoring frames. When using tube and coupler shoring, use
coupler (clamps) made of drop-forged steel, malleable iron, or structural
grade aluminum. Do not use gray cast iron. Do not use couplers
(clamps) if they are deformed, or broken or have defective or missing
threads on bolts, or other defects.
When checking the erected shoring frames with the shoring layout, the
spacing between towels and cross brace spacing should not exceed that
shown on the layout. On metal tubular frame shoring, all locking devices
should be closed. On tube and coupler shoring, check all interlocking of
tubular members and tightness of coupling.
Floor & Wall Openings
Guard all floor and roof holes, skylights, and openings into which persons
Civil Work 45
can walk with an enclosure guard. Or cover them completely with

material and bracing strong enough to support any load. Secure
coverings for floor and roof openings to prevent accidental removal or
displacement.
Guard every stairway and ladderway floor opening on all exposed sides
except the entrance opening. Install a securely anchored standard railing
with intermediate rail and toe-board.
Offset temporary stairway and ladderway entrances, or provide them

with a gate to prevent anyone from walking into the opening. Guard
every hatchway and chute floor opening with a hinged floor-opening
cover. Equip the cover with railings attached so as to leave only one
exposed side. Provide the exposed side either with a swinging gate, or
offset it so that persons cannot walk into the opening.
Guard wall openings from which there is a drop of more than 4-ft (1.2 m)
and the bottom of the opening is less than 3-ft (0.91 m) above the
working surface, with a top rail, top rail and intermediate rail, or standard
guardrail. Provide a toeboard where the bottom of the wall opening,
regardless of width, is less than 4-in. (10 cm) above the working surface.
An extension platform outside a wall opening onto which materials can be

hoisted for handling should have a standard railing. However, one side of
a extension platform may have removable railings to enable handling of
materials.
Civil Work 46
7. Mechanical works:
At any construction site, the main activity will be handling of

material either manually or with mechanical means. About 80% of
the accidents occur while doing this activity. This chapter
exclusively deals with problems encountered while undertaking the
above task.
7.1. Manual handling:
Due to the occurrence of large number of accidents, workers and

managers must know the correct procedures for material handling
and storage to protect their health and safety. The safety
professional must evaluate employee fitness and job tasks to
determine the specific material-handling engineering and
administrative controls and personal protective equipment required.
To reduce the number of injuries caused by material handling, the

project managers should try to minimise the manual handling of
material as much as possible. They can combine or eliminate
operations, introduce ergonomic principles to job design, and move
material mechanically whenever possible. For hazards or jobs that
cannot be mechanised, workers must learn safety techniques to
reduce their risk of injury.
Although physical differences make it impractical to establish safe

lifting limits for all workers, some general principles can be applied.
In manual lifting, worker should make sure the route they must
travel with the object is clear. Next, they should inspect the object
and determine how best to grasp it to avoid sharp edges slippery
surfaces, and other injury-producing factors. 1f mechanical aids are
required (slings, block and tackle etc.) they should be secured
before any lifting is done.
Guidelines for lifting must satisfy four criteria:

- Epidemiological,
- Bio –mechanical,
- Physiological and
- Psycho-physical
Some safe-lifting techniques include two-hand squat lift and team

lifting and carrying.
Mechanical Works 1
Squat lifting emphasises correct placement of feet, straight back and

bent knees, load held close to the body, correct grip, chin in, and
use of body weight to move the object.
Team lifting and carrying emphasises two or more people working in
unison to avoid injuries.
Accessories for manual lifting include hand tools (hooks, crowbars,

rollers), jacks, and hand trucks. Jacks must be inspected regularly
for signs of wear o defects. They should be placed on a clean, level
surface and used with shims and blocks to prevent accidents.
Hand trucks include two-wheeled and four-wheeled carts and trucks.

Workers should be aware of the main hazards
(1) running wheels off bridge plates or platforms,
(2) colliding with other trucks or obstructions, and
(3) jamming their hands between trucks an other objects.
Temporary and permanent storage of materials should be neat and

orderly to eliminate hazards and to conserve space. Materials
storage must be carefully planned to allow adequate ceiling
clearance under sprinklers; to keep aisle and exits clear; to install
adequate bins, racks, and shelving; to secure mechanical lifting
aids; to establish warning signs and signals; and to develop disaster
and emergency planning procedures.
Rigid containers such as metal and box pallets, fibre

board/cardboard boxes, barrels and kegs, rolled paper and reels,
and compressed gas cylinders must be stored to conserve space and
to provide easy access when the material is needed. Uncrated
stock, such as lumber, bagged materials, pipes, and sheet metal,
presents special storage problems. Supervisors must ensure that
these material are secured and will not fall or come loose and injure
workers when being removed from storage.
Hazardous liquid and combustible materials stored containers

require special handling and storage methods to ensure worker’s
safety and health. These containers must be protected from
extremes of temperature or humidity, fire hazards, electrical
hazards, and jarring or excessive movement. Storage areas must
be well ventilated and preferably isolated from other work areas.
Workers must exercise extreme caution when cleaning, removing,
Mechanical Works 2
using, or filling these containers. They must be taught to follow

proper safety procedures and wear protective clothing.
Handling and storage of cryogenic liquids:
The storage and handling of cryogenic liquids (oxygen, nitrogen,

argon, helium, and hydrogen) require careful planning and worker
training. These liquids can cause frostbite on contact with skin and
(except for oxygen) displace breathable air in an enclosed
workspace. To reduce the risks in handling these materials, workers
must know the nature and properties of each cryogen, know how to
operate the equipment, use only approved and compatible
materials, use protective clothing and equipment, know emergency
medical techniques, and be prepared to deal with emergency
situations.
Cryogenic liquids should be stored only in the containers designed

for the particular gas. Containers should be transferred slowly into a
warmer environment to prevent thermal shock to the containers and
equipment. Workers must avoid dropping warm solids or liquids into
cryogenic liquids, never breathe vapours from cryogenic sources,
always check containers for leaks or loss of insulating vacuum, and
use only approved transfer lines to move the liquid from one
container or point to another.
Supervisors of shipping and receiving areas must be aware of

appropriate regulations and labels. Floors must be level, able to
bear the weight load required, and kept clean and slip resistant.
Ramps must have slip-resistant surfaces, be equipped with
handrails, and be clearly marked. Aisles should be wide enough to
allow employees to move about while handling materials and to
allow passage of loaded equipment. Warning signs, mirrors, and
directional markings can ensure that workers avoid collisions and
blind corners.
Workers in shipping and receiving must be trained in the proper use

and handling of such common items as dock-boards, machines and
tools, steel and plastic strapping, burlap and sacking, glass and
nails, pitch and glue, barrels, kegs, drums, and boxes and cartons.
They must also be taught how to load and unload railcars, safely
using mechanical aids and protective clothing.
Mechanical Works 3
Common personal protective equipment used in material handling

includes safety shoes, gloves, goggles, aprons, and leggings to
protect against the most common injuries to hands, feet,
extremities, and eyes. Where workers handle toxic or irritating
materials, they should take showers or wash hands and face
thoroughly at the end of their shifts. The management / contractor
should provide a change of clothing or laundry facilities at the site.
Treating Cold-Contact Burns
Workers will rarely come in contact with a cryogenic liquid if proper

handling procedures are used. However, in the event of contact
with a liquid or cold gas, a cold-contact ‘ Burn ’ may occur. Actually,
the skin or tissue freezes.
Medical assistance should be obtained as soon as possible. In the

interim, the following emergency measures are recommended:
• Remove any clothing that may restrict circulation to the frozen

area. Do not rub frozen parts, as tissue damage may result.
Mechanical Works 4
• As soon as is practical, immerse the affected part in warm

water (not less than 105 F or more than 115 F, 0 C to 46 C ).
Never use dry heat. The victim should in a warm room, if
possible.
• If the exposure has been massive and the general body

temperature is depressed, the patient should be totally
immersed in a warm-water bath. Supportive treatment for
shock should be provided.
• Frozen tissues are painless and appear waxy and yellow. They
will become swollen and painful and prone to infection when
thawed. Do not re-warm rapidly. Thawing may require 15 to
60 minutes. For white people, thawing should continue until
the pale blue tint of the skin turns pink or red. For black
people, assess frostbite by the swelling and blistering of the
skin. Reduction of swelling indicates alleviation of frostbite.
Morphine or tranquillisers may be required to control pain
during thawing and should be administered under professional
medical supervision.
• If the frozen part of the body thaws before the doctor arrives,
cover the area with dry, sterile dressings and a large, bulky
protective covering.
• Alcoholic beverages and smoking decrease blood flow to the

frozen tissues and should be prohibited. Warm drinks and
food may be administered.
• As with any injury or illness, monitor vital signs.
Mechanical Works 5
7.1.1 Winch :
Crabs and Winches may be either hand operated or electrically

driven. Some form of braking or safety lowering device should be
installed, and portable units should be installed securely against
the pull of the hoisting rope or chain.
Under Rule 59, The Building and Other Construction Workers

(Regulation of Employment and Conditions of Service) Central
Rules, 1998 provides the statutory requirements to be complied
with while using the winch. A schematic diagram of the winch is
given below
The operator of this car puller winch stands behind the

shield, which protects the employee if the rope breaks.
The following are some of the guidelines given for the safe
operation of the winches:
• The Safe Working Load of the winch should be marked and

this should never be exceeded.
• Barricade guard should be installed to protect the operator
against flying strand of wire and the recoil of broken ropes.
The operator should also be protected against extreme
weather condition.
• It should be placed on a firm base and properly anchored.
• The brake, ratchet arrangement, gear and pinion including
the meshing, wire rope and its clamping arrangements and
direction of receiving rope drum, tie rods should be checked
before using the winch.
Mechanical Works 6
• Ratchet arrangement should be kept in position while hoisting

a load.
• Tie rod should be adjusted not to allow drum movement
causing clutch arrangement to slip.
• The locking pawl on the ratchet of a winch frequently
presents a serious hazard to fingers of the operator
particularly when he attempts to disengage the pawl. To
reduce this hazard, a small lever may be welded to the pawl
so that it can be safely grasped.
• Hand operated equipment that has a crank handle instead of
a hand wheel poses a major danger if operator loses control
while lowering the load (struck by the revolving handle).
Provide a dog to lock the gears. A pin through the end of a
crank will keep it in the socket during hoisting operation.
• Providing strap brake will be useful when load is to lowered
rapidly.
Mechanical Works 7
7.1.2 Reeving :
If more than one tackle block is used in material handling, the

process of connecting them is termed as REEVING;
Block and Tackle :
A safety factor of 10 is recommended for determining the safe

working load of Manila rope (falls) in a block-and tackle assembly.
This large safety factor allows for
(1) error in estimating the weight of the load,
(2) vibration or shock in handling the load on the tackle,
(3) loss of strength at knots and bends, and
(4) deterioration of the rope due to wear or other causes.
The governing factor usually is the safe working load of the blocks,
rather than of the falls (rope).
By multiplying the number of sheaves and rope parts, the weight of

the load that can be handled by the rope multiplies but does not
correspondingly increase the strength of the blocks. Calculations
show that, in most instances, using a safety factor of 10 for the
rope automatically makes the load on the blocks correspond to the
rope size within safe work load limits. (Mark blocks with their safe
working load. as specified by their manufacturers.) The total weight
on the tackle should never exceed this safe load limit. The safe
work loads for rope used in block-and-tackle assemblies conversely
1 / 10th of the block's breaking strength, based on a safety factor
of 10.
To find the required breaking strength for new rope, proceed as

follows:
1. For each sheave of 3 in. (7.6 cm) in diameter or larger, add

10% to the weight of the load to compensate for friction loss.
2. Divide this figure by the number of ropes or parts running

from the movable block.
3. Multiply the resultant figure by a safety factor of 10.
An example for working out the procedure given above follows:
1. A load to be lifted weighs 2,000 lb (900 kg), and the tackle

consists of two double blocks-four sheaves, four rope parts at
the movable block.
Mechanical Works 8
2. Friction loss (10% for each sheave) = 40% or 800 lb (363 kg).
2,000 + 800 = 2,800 lb (1,270 kg), which divided by 4 (the
number of parts at the movable block) = 700 lb (3 1 8 kg).
3. Applying the safety factor of 10 (10 x 700) gives 7,000 lb
(3,200 kg), the required breaking strength of the rope.
4. New Manila rope of 7/8 in. (22 cm) has a breaking strength of
7,700 lb (3,500 kg) and, therefore, is the proper size for the
load. Synthetic fibres would have greater tensile strength.
The safe work load limit for two double blocks made for rope Of
7/8- in. (22-cm) diameter is 2,000 lb (900 kg)-the equivalent of
the total load in the example.
Attach the rope to the block with a thimble and a proper eye splice.
A mousing of yarn or small rope should be placed on the upper
hook of a set of falls as a precaution against its accidental
detachment.
Inspect blocks thoroughly and frequently, paying particular

attention to parts that are subject to wear.
Figure below shows how tackle blocks should be reeved.
If the sheave holes in blocks are too small to permit sufficient

clearance, excessive surface wear of the rope will occur.
Likewise, excessive internal friction on the fibres will occur if the

diameter of the sheave is too small for the rope.
When using block and tackle in confined spaces, provide guards on

the pulley block so that a person's hands cannot be caught
between the pulley and the rope.
When blocks and falls are used to lift heavy materials or to keep
heavy loads in suspension, as on heavy-duty scaffolds, wire rope is
more serviceable than fibre rope.
Mechanical Works 9
7.1.3 Rigging:
In lifting the various materials and supplies, a number of standard

chokers, slings, bridle hitches, and basket hitches can be used.
Because loads vary in physical dimensions, shape, and weight a
rigger needs to know what method of attachment can be safely
used. It is estimated that at least about 15 to 50% of the crane
accidents are due to improper rigging.
The contractor needs to train those employees who are responsible

for rigging loads about the :-
1. Knowledge of the load
2. Judgement of distance
3. Selection of tackle and lifting gear
4. Proper operational directions to be given.
The most important rigging precautions are to determine the

weight and the size of the load before attempting to lift it. This will
determine the type of equipment and gear to be used and the
method of slinging.
There are various methods of hitching the load to the hook through
choker hitch, basket hitch etc. Some of the types of hitching /
slinging are given below: -
Watch for
broken wires in
This socket must

be replaced
Mechanical Works 10
A wire rope which has been A wire rope which has been
kinked. A kink is caused by subjected to repeated bending
pulling down a loop in a slack over sheaves under normal
line during improper handling, loads. This results in “fatigue”
installation, or operation. Note breaks in individual wires-these
the distortion of the strands breaks are square and usually in
and individual wires. Early rope the crown of strands
failure will undoubtedly occur
at this point.
A “ bird cage” caused by A wire rope which has jumped a

sudden release of tension and sheave. The itself is deformed
resultant rebound of rope from into a “curl” as if bent around a
overloaded condition. These round shaft. Close examination of
strands and wires will not the wires show two types of
return to their original breaks – normal tensile “cup and
positions. cone” breaks and shear breaks
which give the appearance if
having been cut on an angle with
a cold chisel.
An example of “fatigue” failure

of a wire rope which has been A fatigue break in a cable tool
subjected to heavy loads over drill line caused by a tight kink
small sheaves. The usual developed in the rope during
crown breaks are accompanied operation
by breaks in the valleys of the
strands – these breaks are
caused by “strands nicking”
resulting from the heavy loads.
The fiber, wire ropes and chain slings attachments are dealt under
appropriate headings.
Mechanical Works 11
Method of Attachment:
All hooks and rings used as sling connections should develop the full rated
capacity of the sling.
Sockets and compression fittings, when properly attached with wire rope
sling should develop 100% of the rated strength of the wire rope. Swaged
sleeve sling endings should develop 92 to 95% of the wire rope’s strength.
Compression fittings and swaged sleeve fittings are available from the
wire rope manufacturers.
Hand tucked splices develop about 90% of the rope’s strength in ropes
having diameter less than ½” and 80% for larger diameters.
The recommended load rating for a sling assembly is usually based on 1/5
the calculated strength of the assembly.
As a general rule, hooks and rings, oblong links, pear shaped links,
coupling links and other attachments should be made of the same, or
equivalent, heat treatable alloy steel as the chain itself. In most cases the
attachments are provided by the manufacturers themselves.
When rigging irregular shaped loads or heavy loads proper rigging should
be made. Some of the special rigging methods are shown below: -
Identification
tag
Safety lock
The three most common hitches for all types of

Typical Double-chain sling
slings are the Regular, Choker, Basket Hitch.
Mechanical Works 12
Safe Slinging Practices:
Leg length can

be adjusted with
turnbuckles.
1 - Single Vertical 2 – Leg Bridle Hitches

Hitch
NOTE: Load may be

supported on only 2
legs while 3rd leg
balances it.
3-Leg Bridle Hitch
Mechanical Works 13
This hitch
Single Double compresses the
Wrap Basket Hitch load and prevents
it from slipping Pair of Double
out of the slings. Wrap Basket
Double Wrap Basket Hitch
“Double” choker
Use to turn loads
Not recommended
Recommended
Right
Wrong
Chokers do not provide full support for loose loads –

Material can fall out.
Single Choker Hitches
Mechanical Works 14
Types of Slinging and SWL of this Mode:
Load held on
Load held on Two part of
one part of rope rope
Packers to
prevent
chafe
Sling with Choke Hitch

SWL= 0.8 x SWL of rope Simple sling with two legs
SWL= 0.8 x SWL of rope
Load held on two

parts of rope
Sling with two separate legs Endless Sling with Two legs
SWL= 1.25 x SWL of rope and Choke Hitch
SWL= 1.60 x SWL of rope
Load held on four

parts of rope
Packers to
prevent chafe
Packers to
prevent
chafe
Endless Sling with Four Legs Sling with Four Separate Legs
SWL= 1.60 x SWL of rope SWL= 2.00 x SWL of rope
Mechanical Works 15
Sling Calculation: -
When this angle is greater than 450

SWL = SWL (of single vertical hitch) x 3/4
When this angle is less than 450

SWL = SWL (of single vertical hitch) x A/B
Determining capacity of single choker hitch
When this angle is greater than 450

SWL = SWL (of single vertical
hitch) x ¾ x H/L x 2
When the choker angle is less than 450

SWL = SWL (of single vertical hitch) x ¾ x H/L x 2
Determining capacity of double choker hitch
Mechanical Works 16
Special Rigging / Heavy Rigging: -
Double, Triple, quad chain Out - of - balance load by a double sling with
sling to handle loads of chain leg adjusted (Two short chains with
virtually any size or shape. grab hooks attached to the master links.)
Wear
Surfa
Web sling protects roller polished surface

Extreme wear at load bearing surfaces.
Mechanical Works 17
7.1.4. Test Certificates:
THE BUILDING AND OTHER CONSTRUCTION WORKERS

(REGULATION OF EMPLOYMENT AND CONDITIONS OF
SERVICE) CENTRAL RULES, 1996 vide rule 56 require the
employer to ensure that all lifting machinery including all parts and
gears thereof are tested periodically by the competent person before
taking them into use for the first time or after repairs and also after
5 years of their use. Apart from this,these machinery and gear
should be annually examined by a competent person and a record of
the same should be maintained.
The formats in which these are to be maintained are given in

annexes 1, 2, 3 and 4.
The format for keeping the record of annealing of loose gear is given
in annexe 5.
The format of annual through examination of loose gear exempted

from annealing is given in annexe 6.
A record of these tests should maintained in the form of a register as

given in annexe 7.
The pressure vessels should be periodically tested and examined as

per the procedure laid under rule 207 ( as given in annexe 8) and a
suitable record of the same should also be maintained. The format
can be the same as given under Factories Act & Rules.
Mechanical Works 18
7.1.5. Operators and Banksman:
Crane Driver and Slinger:
Normally crane operator tries to do several operations

simultaneously resulting in flying start, jumpy and jerky operation,
quick reversal and sudden stops. In order to avoid these and
provide smooth and safe operations, the following rules are
suggested.
1. Crane controls should be moved smoothly and gradually to

avoid abrupt, jerky movements of the load. Slack must be
removed from the sling and hoisting ropes before the load is
lifted.
2. Centre the crane over the load before starting the hoist to avoid
swinging the load as the 1ift is started. Loads should not be
swung by the crane to reach areas not under the crane ( Figure
below )
3. Crane hoisting ropes should be kept vertical. Cranes shall not

be used for side pulls.
4. Never lower the block below the point where less than two full
wraps of rope remain on the hoisting drum. Should all the rope
be unwound from the drum, be sure it is rewound in the correct
direction and seated properly in the drum grooves, otherwise
the rope will be damaged and the hoist limit switch will not
operate to stop the hoist in the high position.
5. Be sure everyone in the immediate area is clear of the load and

aware that a load is being moved. Activate the warning device
Mechanical Works 19
(if provided) when raising, lowering, or moving loads wherever

people are working to make them aware that a load is being
moved.
6. Do not make lifts beyond the rated load capacity of the crane,
sling chains, rope slings, etc.
7. Do not operate the crane if limit switches are out of order or if

ropes show defects or wear.
8. Make certain that before moving the load, load slings, load
chains, or other load lifting devices are fully seated in the
saddle of the hook.
9. When a duplex hook (double saddle hook) is used, a double

sling or choker should be used to assure that the load is equally
divided over both saddles of the hook.
10. On all capacity or near capacity loads, the hoist brakes should
be tested by returning the master switch or push button to the
OFF position after raising the load a few inches off the floor. If
the hoist brakes do not hold, set the load on the floor and do
not operate the crane. Report the defect immediately to the
supervisor.
11. Check to be sure that the load is lifted high enough to clear all
obstructions and personnel when moving bridge or trolley.
12. At no time should a load be left suspended from the crane

unless the operator is at the master switches or push button
with the power on, and under this condition keep the load as
Mechanical Works 20
close as possible to the floor to minimise the possibility of an

injury if the load should drop. When the crane is holding a load,
the crane operator should remain at the master switch or push
button.
13. When a hitcher is used, it is the joint responsibility of the crane

operator and the hitcher to see that hitches are secure and that
all loose material has been removed from the load before
starting a lift.
14. Do not lift loads with any sling hooks hanging loose. (If all sling
hooks are not needed, they should be properly stored or a
different sling should be used.)
15. All slings or cables should be removed from the crane hooks
when not in use. (Dangling cables or hooks hung in sling rings
can inadvertently snag other objects when the crane is moving.)
16. Crane operators should not use limit switches to stop the, hoist
under normal operating conditions. (These are emergency
devices and are not to be used as operating controls)
17. Do not block, adjust or disconnect limit switches in order to go

higher than the switch will allow.
18. Upper limit switches (and lower limit switches, when provided)
should be tested in stopping the hoist at the beginning of each
shift, or as frequently as otherwise directed.
19. No loads should be moved or suspended over people regardless

of the attachment, mechanical, magnetic, friction, or vacuum.
20. Molten metal shall never be carried overhead where it could

splash onto personnel.
21. If the electric power goes off, place your controllers in the OFF
position and keep them there until power is again available.
22. Before closing main or emergency switches, be sure that all

controllers are in the OFF position so that the crane will not
start unexpectedly.
23. If plugging protection is not provided, always stop the

controllers momentarily in the OFF position before reversing--
except to avoid accidents. (The slight pause is necessary to give
the braking mechanism time to operate.)
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24. Whenever the operator leaves the crane, the following

procedure should be followed:
(a) Raise all hooks to an intermediate position.
(b) Spot the crane at an approved designated location.
(c) Place all controls in the OFF Position.
(d) Open the main switch to the OFF Position.
(e) Make a visual check before leaving the crane.
NOTE: On yard cranes (cranes on outside runways), operators

should set the brake and anchor it securely so the crane
will not be moved by the wind.
25. When two or more cranes are used in making one lift, it is very
important that the crane operators take signals from only one
designated person.
26. Never attempt to close a switch that has an OUT OF ORDER or

Do NOT OPERATE card on it, regardless of whether it is locked
out or not. Even when a crane operator has placed the card, it
is necessary to make a careful check to determine that no one
else is working on the crane, before removing the card.
27. In case of emergency or during inspection, repairing, cleaning,

or lubricating, a warning sign or signal should be displayed and
the main switch should be locked in the OFF position. This
should be done whether the work is being done by the crane
operator or by others. On cab-operated cranes when others are
doing the work, the crane operator should remain in the crane
cab unless otherwise instructed by the supervisor.
28. Never move or bump-another crane that has a warning sign or

signal displayed. Contacts with runway stops or other cranes
shall be made with extreme caution. The operator shall do so
with particular care for the safety of persons on or below the
crane, and only after making certain that any persons on the
other cranes are aware of what is being done.
29. Do not change fuse sizes. Do not attempt to repair electrical

apparatus or to make other major repairs on the crane unless
qualified and specific authorisation has been received.
30. Never bypass any electrical limit switches or warning devices.
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31. Load limit or overload devices shall not be used to measure

loads being lifted. This is an emergency device and is not to be
used as a production operating control.
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7.1.6. Lifting and carrying of excessive weight-
As per Rule 38 of THE BUILDING AND OTHER CONSTRUCTION

WORKERS (REGULATION OF EMPLOYMENT AND CONDITIONS
OF SERVICE) CENTRAL RULES, 1996
“An employer shall ensure at a construction site of a building or

other construction work that
(a) No building worker lifts by hand or carries over-head or over

his back or shoulders any material, article, tool or appliances
exceeding in weight the maximum limits set out in the
following table:
Person Maximum Weight Load

Adult-man 55 kg
Adult-woman 30 kg
Adolescent-male 30 kg
Adolescent-female 20 kg
Unless aided by any other building worker or a mechanical

device. ”
(b) No building worker aided by other building workers, lift by

hand or carry overhead or over their back or shoulders, any
material, article, tool or appliance exceeding in weight the sum
total of maximum limits set out for each building worker
separately under clause (a), unless aided by a mechanical
device.
Mechanical Works 24
7.2. Crane Safety
Derricks and Cranes:
Derricks:
The derricks are normally rigged/fabricated at the site to do a

specific repeated type of job like piling operation, within a small
radius of swing. Rules 67 & 68 of THE BUILDING AND OTHER
CONSTRUCTION WORKERS (REGULATION OF EMPLOYMENT AND
CONDITION OF SERVICE) CENTRAL RULES, 1998 give statutory
guidance regarding the construction of the derrick. The following
diagrams show some of the common type of derricks used at
construction site.
Stiff Leg Derrick
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Frame Derrick
Guy Derrick
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The following guidelines may be followed:
♦ A competent person should ascertain the lifting capacity of the derrick

and it should not be overloaded.
♦ The mast, guy ropes, wire ropes, swivel hook, rope clamps etc., of the
derrick should be thoroughly checked before erecting the derrick.
♦ Depending on the type of derrick, the mast should be firmly fixed by guy
ropes / structure.
♦ All precautions should be taken so that base of the derrick does not shift
or sink.
♦ Guys of the derrick should be anchored tightly with strong structures /
hold fasts/ anchorage blocks
♦ The load being hoisted should not run against the derrick
♦ All welded parts of derricks especially in bracing and stiffeners should be
periodically checked for any crack, or defects in metal itself
♦ If bolted joints are used, check for proper bolts and their tightness
CRANES:
Some of the common types of crane in use at the site are given below:
Mechanical Works 27
JIB CRANE PILLER CRANE
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Mechanical Works 29
According to the site requirement, the crane is chosen.
The Do’s and Don’ts of operation have been given under Ropes and Rigging.
Some of the important requirements as given under THE BUILDING AND

OTHER CONSTRUCTION WORKERS ( REGULATION OF EMPLOYMENT
AND CONDITION OF SERVICE ) CENTRAL RULES, 1998 are given
below:
1. The capacity of the crane should be ascertained before using. Brakes

should be checked while lifting critical load and adjusted if needed.
2. Crane should never be overloaded.
3. Mobile cranes should be parked on hard soil or strong base. They

should not be placed near the edge of the pit or excavation.
4. Safe working load of any mobile crane depends on
• Operator’s skill
• condition of the ground
• Boom length
• Radius of rotation while lifting the load inclination of boom to the
vertical
• out rigger blocked/free
The Safe working load is generally tabulated in the Load chart of the
crane. Sometimes cranes are derated due to the defects in welding,
bend in angle, Bracing etc; and Condition of clutch brake, etc.
The load is the total load, hung from the rope sheaves of the boom
including weight of hook block, ropes/slings, etc.
5. Standard signalling code properly understood by the Operator and

trained signal man should be used. The Crane operator shall respond
to signals only from the appointed signaller but shall obey stop signal
at any time no matter who gives it.
6. Tag lines should be used while hoisting heavy and bulky materials.
Mechanical Works 30
7. The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by Maintenance personnel to ensure
the crane's safe operation.
8. The load being lifted should not touch the boom.
9. The boom or any part of the crane should not come near any live
electric line/service line.
10. Swinging of load should be done smoothly.
11. Proper quality of packing should be used and the outrigger should
rest tightly on the packing.
12. Nobody should stand below the boom or load.
13. The operator should be able to see the hook and load throughout the
hoisting period.
14. During storm, the hook block should be anchored firmly and swing
lock be released.
15. When an extended boom is used on the crane, the operator must use
extreme care in lowering load to the ground. An extended boom
never should be lowered to one side of the chassis for the stability of
the crane is usually reduced in that position and the crane will get
over turned.
16. The crane has to be travelled on a heavy timber mat whenever there
is instability of soil.
17. The use of any make shift methods to increase the capacity of crane
such as timbers, with blocking, or adding counter-weight, should not
be permitted.
18. Before leaving the crane at the end of the workday, the crane
operator should remove the load from the hook and raise the hook
block to maximum height.
19. The crane operator should keep the deck clean of any oil, mud and -
Mechanical Works 31
grease.
20. Operator should always keep the windshield clear, in order to prevent
accident due to this.
21. Ensure atleast two full turns of rope be always on the rope drum.
After a boom extension, the hooks shall be lowered to the required
lowest point to ensure that atleast two turns of rope remain on the
drum and to the highest point to check that the drum capacity will not
be exceeded.
Mechanical Works 32
Mobile Cranes:
Following precautions have to be taken while using, tyre mounted mobile

cranes in addition to the precautions given above.
1. The capacity of the crane should be ascertained before use. Brakes

should be checked while lifting critical load and adjusted if needed.
2. Crane should never be overloaded.
3. Mobile cranes should be parked on hard soil or strong base. They

should not be placed near the edge of the pit or excavation.
4. Safe working load of any mobile crane depends on Operator's skill,

condition of the ground, Boom length, Radius of rotation while lifting
the load, inclination of boom to the vertical out rigger blocked/free.
5. The Safe working load is generally tabulated in the Load chart of the
crane.Sometimes cranes are derated due to the defects in welding,
bend in angle, Bracing etc; and Condition of clutch brake, etc.
6. The load is the total load. hung from the rope sheaves of the boom
including weight of hook block, ropes/slings, etc.
7. Standard signalling code properly understood by the Operator and

trained signal man should be used.
8. The Crane Operator shall respond to signals only from the appointed
signaller but shall obey stop signal at any time no matter who gives
it.
9. Tag lines should be used while hoisting heavy and bulky materials.
10. The brakes, boom, hook, wire ropes and pulleys, rope anchoring
should be checked periodically by a Maintenance person to ensure the
crane's safe operation.
11. The load being lifted should not touch the boom.
Mechanical Works 33
12. The boom or any part of the crane should not come near any live
electric service line.
13. Swinging of load should he done smoothly.
14. Proper quality of packing should be used and the outrigger should
rest tightly on the packing.
15. Nobody should stand below the boom or load.
16. When travelling up a gradient, the load shall be kept in front of the
crane and when travelling down a gradient, the crane should travel in
the reverse and on reaching level ground it should travel in the
normal way otherwise, constant watch on the radius should be
maintained while travelling on uneven surfaces.
17. The mobile crane shall be fitted with suitable horn, Headlights, Side
Lamps, rear and stop lights and flashing direction indicator.
18. Cranes with cantilever type jib, when travelling without load, the jib
should be lowered to a horizontal position.
19. The pneumatic tyres shall be maintained at the correct pressure at all
times.
Mechanical Works 34
Crane Operation Daily Checklist
Crane Operation Daily Checklist For The Month _________ 2001
Name of Site:___________________Operator's Name:______________Lincence No.__________

Crane No.___________________ Model#__________________ Type: _______________________
Date of Inspection: __________________________Date of expiry: _________________by competent person
Description Date Item Number

The following applicable items shall be checked daily, other 1 2 3 4 5 6 7 8 Operators Sign
items may apply. Remark
1.) Test run unit, observe operation for malfunctions 1
2
-Safety, Emergency stop
-Pendant, Joystick
3
-Correct direction of motions 4
-Brakes of all motions 5
6
2.) Check for deterioration or leakage in lines, tanks, valves 7
drain pumps and other parts of air or hydraulic systems 8
3.) Examine load hooks for wear, Cracks, or Damage 9
10
-Saddle wear (10%) Max 11
-Twist (10%) Max 12
-Throat opening (15%) Max
13
4.) Check Hoist Rope, or Chain
14
-End connections 15
Chain-excessive wear, Twist distorted links, stretch 16
Rope- crushing, kninking, broken wires 17
-Latch 18
5.) Check load attachments 19
20
-Capacity ratings, End connections 21
Chain- excessive wear, Twist, Distorted links, Stretch 22
Slings- crushing, Kninking, Broken wires tears 23
6.) Check for excessive wear, Cracks or components
24
25
-Hok block, Sheaves, Hook 26
27
7.) Check all running ropes and chains for correct reeving 28
- Proper spooling 29
30
8.) Check upper limit with no load 31
Code: A= Acceptable D=Defective, Report at Once
Signature of P & M Incharge :
Signature of Site Safety Officer :
Signature of RCM :
Mechanical Works 35
7.3 Erection of Structures:
1. Load should be properly ascertained to identify Centre of

Gravity and load transfer at slinging point, before handling any
equipment.
2. A visual check must be done regarding fitness of all lifting &,

haulage tackles. ropes, slings etc. before every use.
3. The common tendency of checking gear meshing lubrication,

coupling matching, hole matching, etc by feeling with a finger
must be strictly curbed.
4. Selection of Tommy bars, rollers, skids, etc. should made

depending, on the type of equipment to be handled.
5. Eye bolts provided at correct slinging points for heavy

Machinery parts such as motors, generators, turbine, etc.
should be utilised for handling.
6. No sling should be overloaded.
7. Proper quality of pulley block should be used. In no case, pulley

block suitable for fibre rope should be used for steel wire ropes,
while being used as diversion pulleys.
8. No person shall walk, stand or work beneath suspended load.
9. During erection, only one signaller shall give proper signals.

However, a ‘STOP' signal should be obeyed whoever gives it.
Structural Erection:
1. The structural members should be kept in orderly manner on

the ground so that they do not roll down or slide while being
handled.
2. The structural members should be able to be taken out as per

sequence of erection without disturbing the stack. At the same
time, light structures should not be stacked below heavy
structural members where they are likely to be damaged.
Mechanical Works 36
3. Clear passages should be left for easy handling and

transportation of structures.
4. All persons shall stand clear when a crane is sorting or shifting

steel girders or other structural materials.
5. While using spanners, revetting hammers, etc. at heights, they

should be tied with a rope fixed to nearby structure so that they
will not drop on the ground in case of any slip.
6. Only those persons who are skilled in working at height should

be engaged for jobs to be done at height. Persons suffering
from diseases, (epilepsy, blood pressure, etc. or addicted to
drug/alcohol, etc. should not be allowed to work at height.
7. Care should be taken while lifting loads. Proper tag line must
be used for guiding while lifting loads.
8. While positioning a beam or fabricated structure, etc., it shall be

so held that the employee's hand does not get jammed against
other objects.
9. Loose bolt, nuts and tools must be kept in boxes and not on
structures. Boxes must have proper anchorage.
10. Care should be taken to fasten the erected members properly

and to secure by guys, etc. whenever necessary.
11. Providing padding over sharp edges should protect ropes and
slings.
12. Slinging should be carefully done so as to prevent the load from

slipping.
13. Proper sequence of erection should be followed.
14. All electrically operated equipment like grinding machine,

Drilling machine, Welding machine, etc. must have proper
earthing.
15. All safety appliances like safety helmet, gloves, safety belts
must be used in erection site. All persons working at height and
standing on structural members must wear safety belts
equipped with suitable lifeline. Lifeline must be tied to any
independent strong members.
16. In the process of ascending or descending a column and while

placing a truss in position, it may not be possible to use safety
Mechanical Works 37
belts or provide platforms, in such cases, riggers with expertise

in such jobs should be engaged. Use of nets is recommended
while job is done in elevated places, where suitable platform
cannot be provided. If semi -permanent cat-ladders cannot be
provided, rope ladders must be used. Rope ladder should be
placed in position and its top should be tied with individual
strong members.
17. When a column is erected, it should be kept in vertical position

using a minimum of 4' guy ropes unless secured otherwise.
Only after bracing system is fixed the ropes in that axis can be
removed and the other two can be removed only after roof
trusses are fixed.
18. A lot of precautions are to be taken for erecting roof girders and
roof trusses as they are usually slender, very long and unstable
by themselves. The trusses, which have a bracing system,
should be erected first and held by separate cranes and only
after bracing are fixed, the crane should be released. For all
other spans, only purling and horizontal runners need to be
fixed before release of cranes. Roof truss should never be
erected along with monitor roof truss. Monitor roof should be
erected separately.
19. C.G.1 sheets should be lifted manually by proper system. The

man on the roof should use safety belt. C.G.I sheet falling
from a height can cause heavy casua;ty.
20. C.G.1 sheet should be kept tied on the top. The required
number of CGI sheets only should be lifted and unbolted.
Mechanical Works 38
7.4. Use, Care and Maintenance of Slings :
In any construction site the main activity will be handling and

storage of material.
This chapter deals with different types of slings, their use, care and
maintenance.
7.4.1 Synthetic Fibres:
Nylon, Polyester, and polyolefin ropes are the major types of

synthetic fibre ropes used.
Synthetic fibre ropes are used more often than natural fibre ropes
for the following reasons.
• More is known about the properties of various synthetics.

Successful use of synthetic fibre rope depends largely on
selecting the synthetic with physical properties and
characteristics that most closely match the requirements of the
job.
• Splices can be made readily in synthetic fibre rope and can

develop nearly the full strength of the rope. Tapered splices are
highly recommended for rope sizes with a 1-in. (2.5-cm), or
larger, diameter.
Nylon rope:
• Nylon rope has over two and a half times the breaking strength
of Manila rope and about four times its working elasticity. It is,
therefore, well suited to shock loading, such as is required for
restraint lines.
• Its resistance to abrasion is remarkably high in comparison to
other ropes.
• While nylon rope is wet or frozen, its breaking strength is
reduced by 10% to 15%.
• Nylon rope also is highly resistant to organisms that cause
mildew and rotting and to attack by marine borers in sea water.
Mechanical Works 39
• Exposure to air produces little loss of strength over long periods

of time.
• Since there is no swelling, wet nylon rope runs through blocks
as easily as dry nylon rope.
• Although resistant to petroleum oils and most common solvents
and chemicals, nylon's strength is affected by drying oils, such
as linseed oil or the phenols. Nylon rope is also vulnerable to
strong mineral acids, phenolic compounds, and heat.
• Nylon loses some of its strength at 300 F (150 C) and all of it at
482 F (250 C)-its normal melting point. Short of melting, most
of nylon's strength is regained upon cooling to normal
temperature. Nylon of a higher melting point is available.
• Nylon, more than any other rope material, will absorb and store
energy in the same manner as a spring. When nylon rope
breaks, this energy makes the rope's moving ends as dangerous
as a projectile. Exercise caution, therefore, when working nylon
lines around corners, capstans, timber heads, and the like.
Polyester rope:
• The best general-purpose rope available, especially for critical

uses, is made of polyester.
• Polyesters stretch about half as much as nylon, so energy
absorption is also about half as much.
• It is not weakened by rot, mildew, or prolonged exposure to
seawater. Polyester, also, retains its full strength when wet
because it does not absorb moisture.
• It shows little deterioration from long exposure to sunlight and
has good resistance to abrasive wear. Polyester is somewhat
vulnerable to alkalis, but its resistance to ultraviolet light.
• It burns at about 480 F (250 C), and loses strength at
temperatures over 390 F (200 C).
Polyolefin rope:
• In general, polyolefin rope is strong and inexpensive.

• It floats and is unaffected by water. Polyolefin, like polyester,
does not absorb moisture; therefore, it does not shrink or swell
with water. It is unaffected by rot, mildew, and fungus.
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• Polyolefin rope is also highly resistant to a wide variety of acids

(except nitric acid) and alkalis, as well as to alcohol-type
solvents and bleaching solutions. However, it swells and
softens with hydrocarbons, particularly at temperatures above
150 F (66 C).
• The movement of crossed ropes, as well as other types of
abrasion, must be avoided because even modest loads will
cause a sawing motion that leads to a built up of friction.
Descriptions of two types of polyolefin ropes are given below:
• Polypropylene rope, with a specific gravity of 0.91 and a
softening point of 300 F (150 C), is made in several different
size filaments and from film with or without longitudinal
fracturing.
• Polypropylene rope is about 50% stronger than Manila rope,
size for size.
• Pure polypropylene rope has relatively poor rendering
properties. It burns at 330 F (166 C) and loses some strength at
150 E E Polyethylene rope, with a specific gravity of 0.95 and a
softening point of 250 F (120 C), is characteristically slippery
and has very little springiness.
• It is strong and has little stretch.
• Polyethylene rope also has a comparatively low softening point
and low coefficient of friction.
Composite rope :
• Rope made by combining several types of synthetic fibres or by

combining synthetic and natural fibres is also available.
• Composite rope results from attempts to give the surface of the
rope or strand more wear resistance, greater internal tensile
strength, or more structural strength to retain its shape.
Composite rope can be made to match the requirements of
specific jobs.
Working Load :
• Because the safety factor is not the same for all ropes and is
based upon static loading, caution has to be exercised while
using thumb rule. Also caution has exercised when using the
working load figures supplied by the manufacturer.
Mechanical Works 41
• To provide guidelines, working loads are tabulated for rope

(1) in good condition,
(2) with appropriate splices in non critical applications,
(3) under normal service conditions, and
(4) with very modest dynamic loads included.
• It is advisable to Select a higher working load only with expert

knowledge of conditions and a professional estimate of the risks
involved. Factors to consider include:
(1) whether the rope has been subject to dynamic loading or

other excessive use,
(2) whether it has been inspected and found to be in good
condition,
(3) whether it is to be used in the recommended manner, and
(4) whether the application involves high temperatures,
extended periods under load, or obvious dynamic loading,
such as sudden drops, snubs, or pickups.
• For all such applications and for applications involving more

severe conditions of exposure, or for recommendations on
special applications, consult the manufacturer.
• Many uses of rope involve serious risk of injury to personnel or

of damage to valuable property. This risk is often obvious; for
example, a heavy load supported above one or more workers.
An equally dangerous situation occurs if personnel are in line
with a rope that is under excessive tension. Should the rope
fail, it may recoil with considerable force-especially if the rope is
made of nylon. Workers should be warned against standing in
line with the rope. In all cases where such risks are present, or
if there is any question about the loads involved or the
conditions of use, the SWL should be greatly reduced and the
rope should be properly inspected and the manufacturer should
be consulted for recommendations on working loads.
• Dynamic loading automatically voids the working load. Working

load figures do not apply when rope is subject to significant
dynamic loading. Whenever a load is picked up, stopped,
moved, or swung, there is an increased force due to dynamic
Mechanical Works 42
loading. The more rapidly or suddenly such actions occur, the

greater this increase will be. In extreme cases, the force put on
the rope may be two, three, or even more times the normal
load involved, such as when picking up a tow on a slack line or
using a rope to stop a falling object.
• Dynamic effects are greater on a rope with little stretch such as

Manila than on a rope with higher stretch such as nylon.
Dynamic effects are also greater on a shorter rope than on a
longer one. The working load listed contains provision for very
modest dynamic loads. This means, however, that when a
working load has been used to select a rope, the load must be
handled slowly and smoothly to minimise dynamic effects and
to avoid exceeding the provision for them.
• Before placing new rope in service, thoroughly inspect its entire

length to determine that no part of it is damaged or defective.
Any irregularity in the uniformity of appearance is evidence of
possible weakness. There is no agreement on what determines
when a rope should be removed from service. Synthetic rope
damage is not always visible.
• Every 30 days, under ordinary conditions, the rope should be

inspected before taken in to use. The rope should be inspected
much oftener if it is used in critical applications, such as to
support scaffolding on which employees work.
• Inspection consists of examining the entire length of the rope,

inch by inch, for wear, abrasions, powdered fibre between
strands, broken or cut fibres, displacement of yarns or strands,
variation in size or roundness of strands, discoloration, and
rotting.
• To inspect the inner fibres, untwist the rope in several places to

see whether the inner yarns are bright, clear, and unspotted. If
exposed to acids, natural fibre ropes, such as Manila, should be
scrapped or retired from critical operations, as visual inspection
does not always reveal acid damage. Likewise, damage to
synthetic rope is not always visible. If there is a visible core or
core damage, replace or splice out the rope.
Mechanical Works 43
• Natural fibre rope loaded to over 50% of its breaking strength

will be permanently damaged; synthetics loaded to over 65%
may be damaged. Damage from overloading may be detected
by examining the inside fibres. These will be broken into short
lengths in proportion to the degree of overload. To make a
good estimate of the strength of fibres, scratch the fibres with a
fingernail-fibres of poor strength will readily part. This
"fingernail test" is a quick test for chemical damage.
• If the diameter of a rope is worn more than 5 % the rope

should be replaced. In small ropes (up to 1/4in., 19 mm, in
diameter), surface wear that has progressed to the centre of
the twisted element (yarn) may account for more than an 80%
loss of the rope's strength.
• In ropes with a 3/4-1n. (19-mm), or more, diameter, surface

wear may destroy the strength of the cover yarns, yet not affect
the original strength of the core yarns. The remaining strength
of the rope will be in the proportion that the core yarns are to
the original total of yarns. If fibre samples can be secured from
the rope, an estimate of the rope's strength can be made.
Manually break the fibre samples, and estimate the distribution
of fibres in a cross section, quartered to allow for twist
configuration.
• Due to slippage on a supporting surface when under high

tension, synthetic ropes sometime melt on the surface and form
a skin. This skin is the evidence of wear. Rope, using multi-
filament synthetic fibre on the surface, will often "fuzz." This is
due to minute fibre breakage. If a rope is very fuzzy, replace it
and look for the source of abrasion.
Care of Rope Being Used :
• Safe use of different types of rope results from factors such as

chaffing, cutting, elasticity, diameter-strength ratio, and general
anticipated mishandling. To keep rope in good condition, the
following precautions should be observed:
Mechanical Works 44
• If possible, do not drag rope since this wears away the outer
fibres. If a rope picks up dirt and sand, abrasion within the
strands of the rope will rapidly wear it out.
• Handle twisted rope so it retains the amount of twist (called
balance) that the rope seeks when free and relaxed. If rotating
loads and improper coiling and uncoiling change the balance,
restore it by properly twisting the rope at either end. Severe
unbalance can cause permanent damage; localised over twisting
causes kinking or hocking. Kinking strains the rope and may
over stress the fibres. It may be difficult to detect a weak spot
made by a kink.
• To prevent a new rope from kinking while it is being un -coiled,
lay the rope coil on the floor with the bottom end down. Pull
the bottom end up through the coil, and unwind the rope
counter clockwise. If it uncoils in the other direction, turn the
coil of rope over, and pull the end out on the other side.
• Avoid sharp bends over an unyielding surface since this causes
extreme tension on the fibres. To make a rope fast, select an
object with a smooth round surface of sufficient diameter.
• If the object does have sharp corners, pad the corners.
To avoid excessive bending, use sheaves or surface curvatures of

suitable size for the rope's diameter.
• Splice lengths of rope that must be joined. Do not knot them.

A well-made splice will retain up to 100% of the strength of the
rope, but a knot retains only 50%.
• Thoroughly dry out rope that has become wet; otherwise, it will
quickly deteriorate. Do not allow wet rope to freeze. Hang up a
wet rope, or lay it in a loose coil in a dry place until thoroughly
dry. Rope deteriorates more rapidly if it is alternately wet and
dry than if it remains wet.
• Do not use wet rope, or rope reinforced with metallic strands,

near power lines or other electrical equipment. Use of such
rope could cause injury by electric shock to workers.
Mechanical Works 45
7.4.2 Wire rope :
• Wire rope is more widely used than fibre rope. Wire rope has greater
strength and durability under severe working conditions than does fibre
rope. The physical characteristics of wire rope do not change when
used in varying environments. Wire rope has controlled and
predictable stretch characteristics.
Construction
• Wire rope is composed of steel wires, strands, and core. The individual
wires are cold drawn to predetermined size and breaking loads according
to required grades. Grades include iron, tractor, mild plow steel, plow
steel, improved plow steel, and extra-improved plow steel. The wires
are then laid together in various geometrical arrangements according to
construction requirements for strands and classifications of wire rope (6
x 19, 6 x 37, etc.).
• To make a strand, carefully selected lengths of pitch or lay are used.

These lengths have a definite ratio to the length of lay or pitch used in
forming the finished wire rope. After the individual strands are made,
the required number are coiled around the core, which supports the
load-carrying strands. The core can be made of sisal or synthetic fibre;
or it can be a metallic strand core or independent wire rope core (IWRC).
• The service for which the rope is to be used determines the size, the
number and arrangement of wires, the number of strands, the lay, and
the type of core In a wire rope.
Classifications:
• The most popular and most generally used constructions of wire rope are
six-strand ropes of these two classifications-the 6 x 19 and 6 x 37. The
6 x 19 classification contains a variety of constructions for wire rope,
ranging in number of wires per strand from 15 to 26. Typical
constructions are 6 x 19 Seale, 6 x 25 filler wire, and 6 x 19 Warrington.
• The 6 x 37 classification also covers a large number of designs and
constructions for wire rope with the number of wires per strand ranging
Mechanical Works 46
from 27 to 49. Typical constructions of this classification are 6 x 41 filler

wire, 6 x 37, 6 x 36 Warrington Seale, and 6 x 49 filler wire. Generally
speaking, the greater the number of wires per strand, the more flexible
the wire rope. However, the fewer number of wires per strand, the more
abrasion resistant and crush resistant is the rope.
• In ropes with large diameters, 2 in. (6.4 cm) and larger, practically all
wire rope is produced in the 6 x 37 or 6 x 61 class. Therefore, because
of the large number of possible rope constructions that are available,
exercise care to make the proper selection
Service Requirements:
• Depending upon service requirements and conditions, six-strand ropes

may have a fibre core (FC), a wire strand core (WSC), or an RVRC.
Wires in the strands may be laid in the opposite direction (regular lay)
from that of the strands in the rope, or they may be laid in the same
direction (lang. lay) as those of the strands in the rope.
• Where maximum flexibility is required, eight-strand hoisting ropes are
also used. They are usually of the 8 X 19 classification with regular lay
and a FC or IWRC. Flexibility is not a requirement for guy wires,
highway guards, and similar services. Therefore, wire rope of 6 x 7
construction (six strands with seven wires per strand) is suitable. When
selecting wire rope for a particular job, consult engineers from reliable
wire rope manufacturers.
• Some conditions require rope with special qualities. Fibre cores are
affected by temperatures above 250 F (120 C). Under such conditions, a
metallic core provides greater efficiency and safety. A zinc-coated or
stainless-steel wire rope effectively resists some types of corrosion.
• Since preformed wire rope does not unravel, it has advantages for
certain services, such as for slings to hoist heavy construction
equipment. Preformed wire rope is less likely, to set or kink; thus,
broken wires are less likely to protrude and create a hazard to workers.
Mechanical Works 47
Design Factor for Rope Used in Hoisting:
• The operating or design factors for rope used in hoisting are calculated
by dividing the nominal catalogue strength of the rope by the sum of the
maximum loads to be hoisted. It is normal practice to base this on static
loads. It is recommended that hoisting rope have at least the strength
of improved plow steel. For some applications, use extra-improved plow
steel, which is the greatest in strength, to provide an adequate design
factor and better service.
• The minimum design factors for rope used in hoisting depend upon the
type of service required and the state codes covering the particular
hoisting operation. Many of these codes describe exactly how the design
and operating factors should be figured. Therefore, it is prudent to
check what codes are in force before making a final determination or
selection of wire ropes to be used in hoisting. Also obtain the advice of a
reliable wire rope manufacturer.
Causes of Deterioration:
• Deterioration of wire ropes is caused by a number of factors, which vary

considerably in importance depending on the conditions of service. For
example, corrosion often is the principal cause of deterioration of wire
rope used for hoisting in wet conditions. Moisture and the presence of
acid in the water lead to corrosion. Corrosion, particularly of the interior
wires, is indicated by pitting. Corrosion accelerates wear. This highly
dangerous condition is difficult to detect. Among other factors causing
deterioration are the following:
• Wear, particularly on the crown or outside wires, from contact with

sheaves and drums.
• Kinks, acquired from improper Installation of a new rope or from hoisting
with slack in the rope. A kink cannot be removed without creating a
weak place.
• Fatigue, indicated by a square type of fracture at the end of the wire,
can be caused by bending stresses from sheaves and drums with small
radii; by stresses from whipping, vibration, and pounding; or by
torsional stresses.
• Drying out of lubrication, often hastened by heat and operating pressure.
Mechanical Works 48
• Overloading, including dynamic overloading, if acceleration and

deceleration are factors of importance. Damage to wire rope may occur
but not become known until some time after the overload.
• Over winding, when rope length is greater than the drum can
accommodate in a single layer. This can cause heavy abrasion and
excessive wear at crossover points. However, successful over winding
can be achieved by using specially engineered drum grooving.
• Mechanical abuse, such as running over rope with equipment and
permitting obstructions to remain in the rope's path of travel. It is more
common for wire rope to be thrown away because of abuse than from
use.
Lubrication:
When possible, clean a wire rope before lubricating it.

1. Regular application of a suitable lubricant to wire rope used for hoisting
prevents corrosion, wear from friction, and drying out of the core.
2. Good lubricants are free from acids and alkali and have adhesive
strength. They also have the ability to penetrate the strands.
3. The lubricant should be insoluble under the prevailing conditions.
4. Ropes should be dry when lubricant is applied so that moisture will not
be entrapped by the lubricant.
5. Thin lubricants can be applied by hand. However, providing some
means of dripping thin lubricants on the rope, or using a spray device to
apply the proper quantity automatically, is a better way to apply them.
6. Clean wire rope monthly, such as is done in mine shafts. to remove dirt,
abrasive particles, and corrosion-producing moisture.
7. Do not use cleaning fluids on wire rope-they harm the core's lubricant.
Light oils are sometimes used to loosen the coating of lubricant and
harmful materials. Compressed air or steam jet, or other mechanical
method, cleans a rope effectively and thoroughly.
Chain Slings:
• The safety of a chain sling assembly depends on the material used, its
strength for the load handled, method of attaching chain to fittings, and
proper inspection and maintenance. Alloy steel is the standard material
for chain slings because of its resistance to corrosion and wear and high
tensile strength. Hooks and attachments are generally made of the
same material,
Mechanical Works 49
• Chains should be inspected daily by workers, with a six months

inspection conducted by a trained professional. The most common
causes of chain wear include overloading, faulty rigging, or other unsafe
practices. Workers must be trained in proper procedures for using and
inspecting chain sling assemblies.
• Synthetic web slings and metal mesh slings are also widely used in
industry. Synthetic web slings are useful for lifting loads that need their
surfaces protected; however, these slings are easily cut and have little
resistance to abrasion. As a result, these web slings require an initial
inspection, frequent on-the-job evaluation, and periodic formal
inspection by trained personnel.
• Metal mesh slings are classified as either heavy-duty. medium-duty, or

light-duty. They are used to handle sharp edged material, concrete, and
high-temperature loads. Safe use of metal mesh slings is determined by
use of the right sling for the right load and by the construction of the
sling. All metal mesh slings should be labelled to show their safe
working load limit. These slings rnust be inspected regularly, with a
formal inspection conducted once a year. Workers should never shorten
metal mesh slings, twist or kink the legs, or use the sling when the
spirals are locked.
Remove metal mesh slings from service if a broken weld or brazed joint is
discovered along the sling edge. Also watch for the following signs of wear.
Any one of these conditions or a combination of them, if ignored, could
eventually result in sling breakdown:
• broken wires in any part of the mesh

• a loss of 25% in wire diameter due to abrasion
• a lack of sling flexibility
• cracked end fitting
• visible distortion.
A link-by-link inspection should be made to detect the following:
• bent links
• cracks in weld areas, in shoulders, or in any other section of link
• kinks and gouges
Mechanical Works 50
• transverse nicks and gouges.

• corrosion pits
• stretching caused by overloading.
When inspecting the hook, measure between the shank and the narrowest
point of the hook opening. Whenever the throat opening exceeds 15% of
the normal opening, replace the hook. Pay special attention to slings to
which hooks have been added; make sure the hooks are secure.
Safe Practices
Follow these recognised safe practices to prevent chain failures:
• Purchase chain slings complete from the manufacturer. Whenever

repairs are required, send them back to the manufacturer.
• Never anneal or normalise alloy steel chains and hooks. These
processes reduce their hardness and, therefore, greatly reduce their
strength.
• Never splice a chain by inserting a bolt between two links. Never put a
strain on a kinked chain. Train workers to take up the slack slowly so
they can see that every link in the chain seats properly.
• Do not use a hammer to force a hook over a chain link.
• Never remove the permanent identification tags that have been attached
to chain slings by the manufacturer.
• Remember that decreasing the angle between the legs of a chain sling
and the horizontal increases the load of the legs.
• Use chain attachments (rings, Shackles, couplings, and end links)
designed for the chain to which they are fastened.
• See that the load is always properly set in the bowl of the hook.
• Loading on or toward the point (except in the case of grab hooks or
others especially designed for the purpose) overloads the hook and
leads to spreading and possible failure.
• Store chains not in use in a suitable rack. Do not let them lie on the
ground or floor where they can be damaged by lift trucks or other
vehicles.
• Secure "out-of-balance" loads properly.
Operating Practices for all type of Slings:
The following safe practices for all slings are given as guidance:
Mechanical Works 51
• Slings having suitable characteristics for the type of load, hitch, and
environment shall be selected in accordance with appropriate
specifications.
• The weight of a load shall be within the rated load capacity) of the sling.
• Slings shall not be shortened or lengthened by knotting or other
methods not approved by the sling manufacturers.
• Slings that appeared to be damaged shall not be used unless inspected
and accepted as usable.
• Sling shall be hitched in a manner providing control of the load.
• Sharp corners in contact with the sling should be padded with material of
sufficient strength to minimise damage to the sling.
• No portions of the human body should be kept from be the sling and the
load, and from between the sling a crane hook or hoist hook.
• Personnel should stand clear of the suspended load.
• Personnel shall not ride the sling.
• Shock loading should be avoided.
• Slings should not be pulled from under a load when load is resting on the
sling.
• Slings should be stored in a cool, dry, and dark place to prevent
environmental damage.
• Twisting and kinking the legs (branches) shall be avoided.
• A load applied to the hook should be centred in the base (bowl) of the
hook to prevent point loading on the on the hook.
• During lifting, with or without a load, personnel shall be alert for possible
snagging.
• In a basket hitch, the load should be balanced to prevent slippage.
When using a basket hitch, the sling's legs (branches) should contain or
support the load from the sides above the centre of gravity.
• Slings should be long enough so that the rated load (rated capacity) is
adequate when the angle of the legs (branches) is taken into
consideration.
• Slings should not be dragged on the floor or over an abrasive surface.
• In a choker hitch, slings shall be long enough so the choker fitting
chokes on the webbing and never on the other fitting.
• Nylon and polyester slings shall not be used at temperatures in excess of
194 F (90 C).
• When extensive exposure to sunlight or ultraviolet light is experienced
by nylon or polyester web slings, the sling manufacturer should be
Mechanical Works 52
consulted for recommended inspection procedure because of loss in

strength due to such exposure.
7.4.3 Lifting gears:
Sheaves and Drums:
• Fatigue of wire rope resulting from bend' g stresses depends upon

drums' and sheaves' diameters-the larger the diameter of the drums and
sheaves, the more favourable will be the rope's life. However,
sometimes a sacrifice must be made because of designs and
considerations for other equipment. Many types of equipment
successfully operate with smaller drum-and-sheaves rope ratios, while
others use much larger ratios.
• The safety and the service life of installations for hoisting rope can be
greatly increased by using sheaves and drums of suitable size and
design and by properly lubricating them.
• Maintenance of the rope and of the hoisting equipment is also required.
• It is essential that heads, idlers, knuckles, curved sheaves, and grooved
drums have grooves that support the rope properly. Before installing a
new rope, inspect the grooves, and, where necessary, machine them to
proper contour and groove diameter.
Mechanical Works 53
Sheaves:
• The condition and contour of sheave grooves Is important for the service
life of wire rope. Periodically check sheave grooves (Figure 10-4), and
do not let them wear to a smaller diameter than those shown for used
grooves in Table 10-G. If they become worn more than this, expect a
reduction in the rope's service life. Reconditioned sheave grooves
should conform to the tolerance, shown in Table 10-G, for new (or re
machined) grooves.
• On all new sheaves, the grooves should be made for the size of rope
specified. The bottom of the groove should have a 150-degree arc of
support, and the sides of the groove should be tangent to the ends of
the bottom arc. The depth of the groove should be one times the
nominal diameter of the rope. The radius of the arc should be one-half
the nominal rope diameter plus one-half the value.
• Check sheaves for proper alignment when they are installed. During
rope changes, check the sheaves for worn bearings, broken flanges,
proper groove size, smoothness, and contour. Recondition or replace
heavily worn or damaged sheaves.
• Sheave groove bearing pressures can become very hot depending upon
operating conditions and rope loading. High pressures can cause
excessive sheave wear and shorten the life of wire rope. It is necessary,
therefore, to consider this factor and to select proper sheave materials
and liners at the time of installation. Information on this subject may be
found in most wire rope manufacturers' handbooks.
Mechanical Works 54
Recommended Tread Diameters of Sheaves and Drums for Wire Rope
Average
Rope Recommended
Classification (times rope diameter) Minimum
6x7 72 42
6x19 45 30
6x37 27 18
8X19 31 21
Drums:
• Avoid multiple-layer winding of rope on drunk if possible. Multiple

layering causes the rope to wear thus shortening the rope's life,
particularly at the point where the rope rises to the next layer. Where
practical, use drums wide enough diameter and length that they can
take all the rope in a single layer.
• Minimise crushing and excessive wear of wire rope using spirally grooved
drums with capacity for one layer rope. In any case, limit the number of
layers to three. Rope lifters at the flanges are recommended when two
or more layers are wound on drums. To distribute wear uniformly
crossover points, cut off one-and-a-quarter wraps every 6 months or
three or four times during the life of the rope. In no case should there be
fewer than two full wraps on a drum; three is preferred.
• In general, avoid reverse bending of wire rope (bending first in one
direction and then in the opposite) over sheaves or drums. This wears
out the rope faster.
• Correct fleet angle is important for even, efficient winding of wire rope.
The fleet angle is the included angle between the rope winding on the
drum and a line perpendicular to the drum shaft and running through
the head or lead sheave.
• To reduce any tendency for the rope to open-wind, do not let the fleet
angle exceed 1o30'. To assure the rope's starting back on the next
Mechanical Works 55
layer, use a minimum angle of 0030’ for smooth drums and 2o for
grooved drums. Adhering to these 'fications helps achieve uniform
winding on smooth-faced drums and also increases the winding
efficiency of grooved drums. For smooth-faced drums, proper direction
of lay of rope for specified winding conditions further helps achieve
uniform winding.
• Installing a wire rope on a plain- or smooth-faced drum requires a great
deal of care. The starting position should be at the drum end so that
each turn of the rope winds tightly against the preceding turn. Maintain
close supervision during the entire installation process to make sure
that:
1. the rope is properly attached to the drum
2. appropriate tension on the rope is maintained as it is wound on the
drum
3. each turn is guided as close to the preceding turn as possible so that
there are no gaps between turns
4. there are at least two dead turns on the drum when the rope is, fully
unwound during normal operating cycles. Loose and uneven winding
on a plain- or smooth-faced drum, can, and usually does, create
excessive wear, crushing, and distortion of the rope. The results of
such abuse are lower operating performance and a loss in the rope's
effective strength. Also, on jobs that require moving and spotting a
load, the operator will encounter control difficulties because the rope
will pile up, pull into the pile, and fall from the pile to the drum
surface. The ensuing shock can break or otherwise damage the
rope.
Pulleys:
• Proper pulleys should be used, according to the requirement of work

• In no case pulley meant for Manila/ Nylon rope should be used with steel
rope.
• Sheaves, Shaft, Hook pin, Locking pins should be checked before use
and lubrication done on necessary parts.
• Grooves of the sheaves should be uniform and smooth. The wire rope or
fibre rope should run free without touching against the block or
suspension parts.
• Sheaves should rotate freely on the shaft.
• The shaft should be free from crack and should not be worn out.
• Anchorage should be strong and firm.
Mechanical Works 56
• Anti twister should be used to prevent rubbing of ropes against one

another.
Groove Diameter in Relation to Wire Rope Diameter
Amount that Groove Diameter
Should Be Larger than Nominal
Rope Diameter (inches)
Rope Size (inches) Used New
1/4 and 5/16 1/128 1/64
3/8 to 3/4 incl. 1/64 1/32
13/16 to 11/9 incl. 3/128 3/64
1- 3/16 to 1- 1/2 incl. 1/32 1/1 6
1- 3/16 to 2- 1/4 incl. 3/64 3/32
2- 5/16 and larger 1/16 1/8
Chain Block / Pulley Lift :

• 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 as specified by the
statue. It should be lubricated before every use.
• No cannibalising should be done on the chain block.
• Chain block should be tested for slip by suspending safe load.
• It should operate freely and the chain should not come out of the pulley.
• The anchorage should be strong and rigid.
• They should be checked for cracks, excessive wear and tear, elongation,
etc. Hooks which are opened out should not be used.
• No chain block or pulley which has been tampered, be used unless it is
thoroughly checked and tested by competent person as laid down under
the relevant statute.
• Chain block / pulley must be checked if stored for a long time, by
subjecting to shock load, to observe slipping of load, jamming of links
etc.
Mechanical Works 57
Link tend to
close – up Bend
and
elongate
Stretched
Link
Twisted Wear
Link
Bend
Remaining Material
Cuts
Mechanical Works 58
HOOKS:
Inspect and discard if:

• Throat opening exceeds 15% of original opening
• Twist exceeds 10o along the vertical axis
• Deep nicks and gauges are observed
• If loss of metal due to filing is more than 1/64th for 1” depth of the hook
• Wear in the hook exceeds 8% of the depth
Normal Defective –
Throat Open
Throat opening
more than 15% -
Hook should be
rejected
Defective – Defective – Hook bent

Hook worn out
Worn out Bent

hook
Mechanical Works 59
SHACKLES:
Inspect and discard if
• Wear exceeds 8% of the diameter

• Body is distorted
• Damage to thread on pin or body is observed
Rope Fittings:
There are several ways to attach wire rope to fittings:

pressed fittings, mechanical sleeve splices, hand-tucked splices, clips and
clamps, sockets, and knots.
Fittings are important for safety because they develop from 75% to 100%
of the breaking strength of the rope. Manufacturers also specify fittings of
suitable size and design for ropes of different sizes.
The strength of an attachment is attained only when the connection is

made exactly according to the manufacturer's instructions.
Some types of attachments, such as pressed fittings or mechanical sleeve

splices that are used in making slings, must be made at either a wire rope
manufacturer's plant or at a properly equipped commercial sling shop.
Efficiencies of properly made hand-tucked splices vary according to the

splicer's ability and the rope's diameter but can be as high as 90%.
The efficiency of mechanical sleeve splices varies from 90% to 95% when
IWRC-type wire rope is used.
Rope often is connected to the fittings of conveyances by means of clips

and clamps. They are rated to develop 75% to 80% of the rope's breaking
strength. It is important to retighten the nuts on all clips after the rope's
first load-carrying use, as well as at all subsequent regular inspection
periods.
Mechanical Works 60
Socketing with zinc and a thermostate plastic resin will develop 100% of
the rope's breaking strength.
Since there is no ready way to detect flaws in the finished job, follow the
recommended procedure exactly.
In high-speed hoisting, fatigue is especially likely to develop with this type

of attachment. For this reason, cut off and discard, at frequent intervals,
the section adjacent to the conveyance.
Square knots and other types of knots have low and unpredictable
efficiencies-40% or less. Using them is likely to result in the failure of a
rope assembly and under certai conditions to result in serious accident.
Inspection and Replacement:
The frequency of inspections and replacement of rope depends on service

conditions. Some plants and mines, for instance, make a daily inspection
for readily observable defects, such as kinking and loose wires, and a
thorough inspection weekly.
For the latter inspection, the rope speed is generally less than 60 feet per
minute (fpm).
The supervisor checks specifically for wear of the crown wires, kinking, high
strands, corrosion, loose wires, nicking, and lubrication. Rope callipers and
micrometers are used to determine changes in the cross section of rope at
various locations.
In most cases, sudden change in rope length and/or diameter is a warning

that the wire rope is nearing the end of its useful life and that it should be
removed from service. The reason for this change is general deterioration
of the structure of the interior rope, such as corrosion of uninspectable
wires and general deterioration of the core of wire rope. A decrease in the
rope's diameter, which may also occur, is difficult to determine in many
cases.
The number of broken wires per lay is one of the principal bases for judging
the condition of a rope. If most of the broken wires in a lay are
concentrated in several strands, that section of the rope is weaker than it
Mechanical Works 61
would be if the broken wires were uniformly distributed throughout all

strands and along the length of the rope. If, however, the number of
broken wires along the length of a rope increases rapidly between
inspections, the rope is becoming fatigued and nearing the end of its useful
life.
Inspection codes are given in the statutes.

Usually inspections are based on numbers of broken wires per strand in one
rope lay or number of broken wires per rope lay in all strands. Electronic
inspection devices are available for determining loss of strength due to
corrosion, loss of metallic area, and broken wires.
Experience and judgement of all these factors, combined with the length of
time the rope has been in service and the tonnage hoisted, or other work
done by the rope, determine when it should be discarded and replaced. At
intervals throughout the life of the rope, a short section should be off at the
socket end. This practice has two purposes:
1 remove wires damaged by vibration dampened at the socket and
2 to change the positions of critical wear poi throughout the system.
Mechanical Works 62
7.5 Hoists
Material hoists and personnel hoists are made of tubular steel. Be

sure to consult with tubular steel manufacturers or suppliers for
current technical data. The plant supervisor or the contractor must
comply with the manufacturer’s specifications and limitations.
Hoists may be erected in hoistways inside the building or in outside

towers. Personnel hoists are used just for the transport of people.
Never permit personnel to ride on a material hoist. Do not permit
work in or on the hoistway while the hoist is in operation.
Post the rated load capacities, recommended operating speeds and

special hazard warnings or instructions on cars and platforms.
Inside Material Hoistways
If the material hoist is installed inside the building, enclose the

hoistway. Solid enclosure is preferred. However, heavy wire
screening, ½-in. (1.25 cm) mesh, No 18 US gage wire, is often
substituted. Partition adjacent hoistways.
Protect entrances by solid or slatted wood gate at least 5-ft (1.7m)

high and within 4-in. (10 cm) of the hoistway. Counter-weight
gates and use latching or locking mechanisms.
Provide protective covering of heavy planking below the cathead of

all hoists. This will prevent objects from falling down the hoistway.
Outside Material Hoistways
Hoisting towers are usually made of tubular steel and are used on
construction sites. Base the design on a safety factor of at least
five. Erect the tower on a level and solid foundation, and have it
well guyed or fastened to the building.
Enclose the tower with heavy wire screening and equip it with a
fixed ladder extending the full height of the tower. Install standard
railings and toe-boards on runways connecting the tower to the
building.
Mechanical Works 63
Material Hoist Platforms
Build material hoist platforms with a safety factor of at least five.

Use timer not less than 2-in. (5 cm) for flooring. Enclose sides not
used for loading with heavy wire screening, and provide 6-in (15
cm) toeboards. Install an overhead plank covering at the
crosshead. The covering can be built in hinged sections to permit
handling of long material. Where wheelbarrows are handled, attach
stop cleats to the floor. Equip the car with a broken-rope-type of
safety device. If a car’s cable breaks, the car safety clamps or
dogs are then thrown into position on the guide rails to stop the
car.
Signal Systems
A good signal system is necessary to safety operating hoists.

Electrically operated lights or bells, bells operated by pull cords, a
combination of bells and lights, or telephone system can be used.
Adopt standard signals and post them at each entrance and at the
engine.
Personnel Hoists
Any hoist used for carrying passengers should conform to the safety
requirement of BSI. Rack and pinion hoists can be used to carry
personnel or material but never both, according to strict
manufacturing specifications and safety rules. Include all safety
devices, including an over-speed governor, normal limit and final
limit switches and thoroughly inspect and maintain the hoist
regularly.
Temporary use of permanent elevators. Permanent passenger

or freight elevators in buildings under construction modification or
demolition may be used for carrying workers or material or both.
However, they must be approved for such use and a temporary
permit must be issued for the class of service.
Tower, masts and hoistway enclosures. Design and install the

tower or mast construction that forms the supports for the
Mechanical Works 64
machinery and guide members to support the load and forces

specified. For hoists located outside of a structure, the enclosures
(expect the one at the lowest landing) may be omitted on the side
where there is no floor building’s side of the hoistway should be full
height or a minimum of 10-ft (3 m) at each floor’s landing.
Enclosure at the pit should be not less than 8-ft (2 m ) on all sides.
For hoists located inside a structure, enclose the hoistway

throughout its height. Construct hoistway enclosures so that when
they are under a horizontal pressure of 100 lb. (445 N)
• they cannot deflect more than 1-in (2.5 cm)

• The running clearance between the car and the hoistway
enclosure is not reduced below ¾-in (2 cm) except on the sides
used for loading and unloading.
If the open-work, provide hoistway enclosures with an unperformed

kick plate on all sides within the building or structure. The kick plate
should extend not less than 12-in. (30 cm) above the level of each
floor above the lowest.
Foundations of hoists should distribute the transmitted load, as not

to exceed the safe load-bearing capacity of the ground upon which it
is set. Anchor hoist structures to the building (or other structure)
at vertical intervals not exceeding 25-ft (8 m). If tie-ins cannot be
made, guy the hoist structure to adequate anchorage for stability.
When wire rope is used for guys, it should be at least ½ -in (2 cm)
in diameter. Tie-ins should conform to, or be equal to, the
manufacturer’s specifications and should remain in place until the
tower or mast is dismantled.
Where multiple hoistways are used and one or more of the cars are
designed solely as a material car in accord with ANSI 10.5 personnel
cars are prohibited. Each personnel hoist should be independently
powered and operated. Never use Chicago booms on a hoist
structure.
Doors or gates for hoistways should not be less than 6 ½ -ft. (2 m)

high. If a solid door is used, it should have a vision panel, not wider
than 6-in. (1.5 cm) and not larger than 80-in (0.05 m2), covered
Mechanical Works 65
with expanded metal. Protect all hoistway entrances with

substantial gates or bars.
Landing doors should lock mechanically so they cannot be operated

from the landing side. At landings other than the lowest one, use
locks that can be released only by a person in the car. Some doors
at the lowest terminal landing automatically lock when closed with
the car at the landing. In such cases, provide a means to unlock the
car from the landing side to permit access to the car. Never use a
hook and eye as a door-locking device.
Car platforms. Each car should have a platform or protective

covering that extends over the entire area of the car’s enclosure.
The covering should be non-perforated, fire retardant and supported
by the car’s frame. Design the frame and the floor to handle the
anticipated loads.
Car enclosures. Enclosures and linings of cars should be made of

metal or fire retardant wood. Permanently enclose personnel hoist
cars on the top and all sides, except the entrance and exit. Securely
fasten this enclosure to the car’s platform. Support the enclosure so
that it cannot become loosened or displaced when the car’s safety or
buffer is engaged. Make the enclosure’s walls strong enough so that
their running clearance is reduced by no more than ¾ in. (2 cm)
when a force of 100 lb (445 N) is applied horizontally to the walls of
the enclosure.
Provide an emergency exit with an outward opening cover in the top

of all cars. The opening should be not less than 400-in.2 (10.16 m)
in area, with a minimum dimension of 16-in. (0.41 m). It should
provide a clear passageway unobstructed by fixed hoist equipment
on or in the car. Use wire glass, or the equivalent, for vision panels.
Use plain glass only for car’s operating appliances.
Do not locate a working platform on top of the hoist car, unless

specifically provided in ANSI A10.4, Safety Requirements for
Personnel Hoists Do not place equipment that is not required for the
operation of the hoist or its appliances, on the top of the hoist car.
Require that the hoist be locked out per lockout / tagout procedure
prior to performing repairs.
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Wire Ropes & Sheaves
Use hoisting ropes not less than ½-in. (1.25 cm ) in diameter except
on such equipment as small winches, like those on gin poles. In any
case, they should provide a safety factor conforming to the
requirements of applicable elevator codes. Inspect ropes frequently
and keep them lubricated. Replace ropes when inspection discloses
that wear, breakage, or corrosion has reduced their strength below
the permitted safety limit.
Where clip fastenings are used, there shall be at least three clips,
with the U-side on the dead end of the rope. Ropes shall be
guarded at points where persons may come in contact with them
and where objects may strike or rub against them. Keep sheaves
aligned and bearings lubricated. In general, sheaves diameter
should be at least 20 times the rope’s diameter.
Hoisting Engines
Do not locate hoisting engines in public streets. If they must be

located there, enclose them with barricades to protect the public. In
any case, install a roof to protect the equipment and operator from
the elements.
Engines should have brakes that can stop and hold 150% of the
rated safe load. In addition, engines should have a pawl for holding
suspended loads.
Enclose exposed gears, shafting and couplings. Cover exposed

steam pipes and place exhaust pipes where steam cannot strike
nearby persons.
Where electric hoists are used, install enclosed safety-type switches.

Enclose or guard all current carrying parts to prevent personal
contact and ground installation.
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7.6 Other Mobile Machinery & their Movement at the Site:
At the construction site number of mobile machinery are used apart

from cranes. They cause a large number of accidents. Hence it is
imperative to use them safely. This chapter deals with some of the
most commonly used mobile machinery at the site.
Trucks and other mobile equipment:
Contractors working at the site should take great care to prevent

their trucks and other mobile equipment from colliding with
pipelines, power lines, and other equipment. In this way, they will
avoid interrupting the operations at the site.
Before mobile equipment is moved, contractors should survey the

area in which it is located to check for overhead wires, pipelines
excavations, invisible ground conditions, and similar hazards.
Timber mats may have to be provided for providing firm footing.
Equipment with high clearances, such as cranes, should not be

moved into or out of, or operated in, any area containing electric
power lines until the approval of the superintendent has been
obtained. No part, including the load, may reach within 10-ft (3 m)
of electric lines carrying up to 50 kV and an additional 4-in. for every
10 kV above 50 kV, unless power in the lines is shut off. Details
have been given under chapters captioned
“Cranes ”and “Electrical hazards”.
Powered Trucks:
One method of handling construction deliveries by trucks is to have

a signaller serve as the eyes for the truck driver. If there is no
signaller, install reverse alarms on all heavy mobile equipment and
trucks. Also be sure barricades, guard-rails, and warning signs are
in place to assure maximum safety.
When trucks, bulldozers, powered wheelbarrows, and other

mechanised construction equipment are to be operated within a
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plant, the contractor and the plant's management should agree upon
the traffic flow. In that way, the areas in which the construction
equipment is to be operated will be known and isolated where
possible. The contractor’s key personnel and the plant's designated
personnel should receive drawings of these areas.
To avoid extra handling and vehicle movement, contractors should

be notified by the site officials about the exact location to make
deliveries.
Sometimes it may be necessary to transport employees in trucks

from one location to another within the work area. Unless this is
controlled, this operation can become a major source of serious
injuries.
In tractors and trailers, the coupling mechanism must be carefully
safeguarded and loads secured to the trailer. Motorised hand trucks
must be safeguarded
(1) to prevent the operator from being pinned between the truck
and a fixed object and
(2) to prevent the truck running up on the operator's heels.
Automated guided vehicles must have some means of stopping

should someone step in front of them. Such trucks should be
equipped with flexible bumpers that shut off power on contact.
Operators of industrial trucks can prevent accidents by using the

same safe driving techniques they employ on the highways. They
need to observe speed limits, exercise care in backing up, stop at
blind corners and doorways, keep trucks a safe distance apart, avoid
driving trucks into elevators unless authorised, and exercise caution
at railroad crossings.
Loading and unloading trailers require careful procedures to avoid

accidents. Operators should make sure the brakes are on, wheels
are blocked, loads are neatly stacked and stable, and the load is
fastened to the trailer securely.
Industrial trucks should not be used for any purpose other than the
one for which they were designed.
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Operators are responsible for the care of trucks and should never
leave a truck unattended, park in an aisle or doorway, idle engines
for too long, or ignore mechanical problems.
When driving, they should keep arms and legs inside the truck's
guard or operating station, keep passengers off the truck, and watch
out for pedestrians.
Industrial powered trucks should be inspected and overhauled

regularly.
Operators should inspect their trucks before and after each shift.
Repairs, replacements, or other work should be performed only by
trained mechanics wearing proper protective equipment, particularly
when handling electrically powered trucks. Repairs or re-fuelling of
gasoline and liquefied petroleum trucks should be done as per
norms/instructions to avoid health hazards and burns and
explosions. Only authorised fuel and fuel tank equipment should be
used on these trucks.
Operators must have a valid driver's license, good driving record,

and few, if any traffic violations. Contractors must carefully select
trainees to meet certain physical and mental qualifications required
by safety standards. Training programs should centre on company
policies, operating conditions, and types of trucks used.
Management should maintain records of each employee's driving
performance.
Secure all equipment being towed not only with a regular hitch or
drawbar but also with a safety chain attached to the pulling unit. A
drawbar failure can result in a serious accident.
When towing a scraper from one job to another, the operator should
use a scraper bowl safety latch, or place a safety bolt in the beam to
give maximum clearance for road projections such as at crossings.
This precaution prevents the bowl from striking the ground or
pavement and injuring persons or damaging equipment.
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Clearing work:
Work requiring exposure to low limbs of trees or to high brush

involves serious hazards. Suitable protective measures and safe
practices can readily eliminate these risks
When using a bulldozer, equip it with a heavy, well-supported,

arched steel-mesh canopy to protect the operator. The operator also
should wear goggles to shield the eyes from whipping branches.
Head protection guards against injuries from falling branches. When

a bulldozer shoves hard against the butt of a large dead tree, the
tree may crack in the middle or limbs may fall onto the machine.
Dead branches or tops also can drop from live trees. A safe
procedure to eliminate the danger is to cut the roots on three sides
and then apply the power to the fourth side. Use a long rope to pull
over large trees, but make sure in advance that the tractor and
operator will be in the clear when the tree falls. Operators should
ensure that all workers in the area are out of harm's way before
pushing over any trees, bulldozing rock, and rolling logs.
Special hazards:
Fatalities can occur easily when equipment is used on dumps and

fills, near excavations, and on steep slopes. The operator should
keep the bulldozer blade close to the ground for balance when the
machine is travelling up a steep slope.
When a worker is driving a tractor-dozer down a slope, the person

should doze three or four loads of dirt to the edge of the slope,
keeping the loads in front of the blade. If the dirt is lost on the way
down, the operator should not lower the blade to regain the load
because of the danger of overturning. Never use the blade as a
brake on a steep slope except in cases of extreme emergency.
Ground’s conditions will determine how close to an excavation or the

crest of a dump and operator safely work a machine. Wet weather
means the operator must work at a greater distance from the edge
or crest. When the ground is treacherous, assign someone to signal
the driver.
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Sometimes employees, the public, livestock, and property are

endangered when material is pushed over the edge in side hill work.
In such cases, make sure there is sufficient clearance below before
the work begins.
Some Useful tips for Safe Operation:
Don't allow anyone to stand on the running board or bed of a truck,

or sit at the side or end of a flatbed truck.
Provide seats for each person if required to ride on vehicled

equipment.
Supply safety belts for all passengers who ride in the cabin with the
driver.
Do not permit workers to ride on a loaded truck or other machines

not equipped for the purpose.
When people are boarding or descending from a truck, the truck

should be standing still.
Prohibit workers from getting off or on moving equipment. Provide a

boarding ladder. If necessary, provide a bus to transport employees
to
the work site.
Vehicles that will be moving slower than normal traffic at night

should have a yellow flashing light or four-way flashers visible from
all directions.
Equipment left unattended at night, adjacent to a highway in normal

use, or adjacent to construction areas where work is in progress
should have lights or reflectors, or barricades equipped with lights or
reflectors to identify the location of the equipment.
Whenever equipment is parked, operators should set the parking

brake. Equipment parked on inclines should have the wheels
chocked, or track mechanism blocked, and the parking brake set.
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Bulldozer blades and scraper blades, end loader buckets, dump

bodies, and similar equipment should be either fully lowered or
blocked when being repaired or when not in use.
Personnel should not work or pass under the buckets or booms of

loaders in operation.
No modifications or additions that affect the capacity or safe

operation of equipment should be made without the manufacturer's
written approval.
Tools should not be left suspended from cranes, hoists, etc.
Guarding, safety devices, platforms, and means of access:
Provide guarding for belts, pulleys, sheaves, gears, chains, shafts,

clutches, drums, flywheels, and other reciprocating or rotating parts
of equipment.
Do not remove or make ineffective any guard, safety appliance, or

device unless immediate repairs or adjustments are required, and
then only after the power has been shut off. Replace guards and
devices as soon as repairs and adjustments have been completed.
Properly insulate or guard current-carrying parts of electrically

operated equipment. Properly ground all non-current-carrying metal
parts.
Cover high-temperature lines and equipment, located where they

endanger employees or create a fire hazard, with suitable insulating
materials.
Properly release exhausts from all equipment powered by steam or

internal combustion engines (carbon monoxide hazard) and also,
locate them so that they do not endanger workers or obstruct the
view of the operator.
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Install platforms, footwalks, steps, ladders, handholds, guardrails,

and toeboards on all equipment where they are needed to provide
safe access.
Provide suitable floors or platforms, surfaced with slip-resistant

material, for all equipment operators.
Operators of equipment should be protected against the elements,

falling objects, swinging loads, and similar hazards. Be sure that
windows in cabs or enclosures on equipment are made of safety
glass and kept in good repair at all times.
Provide safety devices to prevent unauthorised persons from starting

equipment. This could simply be a key ignition system or simply
blocking and locking the starter. At the end of a work shift,
operators should set and lock equipment. This prevents it from
being released, dropped, or activated in any way. The
manufacturer's procedure for shut down should be followed.
Do not permit debris, oil, grease, oily rags, and waste to accumulate
on equipment.
Post safe load capacities and operating speeds on all equipment.
Be sure each piece of equipment is placed on an adequate

foundation and properly secured.
Flammable liquid:
Prohibit refuelling of gasoline-operated equipment while the motor is

running. Allow continuously operating equipment to be fuelled only
from properly protected tanks located outside the work area. Tanks
should be adequately grounded and bonded to equipment to prevent
static electricity build-up.
Do not locate fuel-tank filler openings in such a position that spills or

overflows can run down on a hot motor, exhaust pipes, or battery.
Prohibit smoking or the use of open flames on, or in the immediate

vicinity of, gasoline-operated equipment while it is being refuelled.
Mechanical Works 74
Workers should not use solvents with flash points below 100 F (37.8
C) for cleaning equipment or parts.
When gasoline and other highly flammable fluids are used, transfer
them by approved pumps or store them in approved safety cans. Do
not store gasoline, fuel oil, and other flammable or combustible
liquids on equipment except in fuel tanks or approved safety cans.
Locate suitable fire extinguishers on, or close to, each industrial

truck.
Repairs:
Shut down all hazardous equipment for repairs.
Post suitable signs, and do not remove them until repairs have been
completed.
Move mobile equipment, if possible, to a safe location where

operations will not interfere with the repair work.
Block or crib equipment suspended in slings or supported by hoists

or jacks for repairs before anyone is permitted to work underneath
it.
For repairs on equipment made away from the source of power, such
as conveyors and cable ways, use chains, blocking, or similar
devices. Such precautions will prevent injury in case the equipment
is accidentally started.
Before repairs on electrically powered equipment are begun, lock the

main switch in the open (OFF) position. The person doing the
repairs should retain the key to the switch lock. If there is more
than one repairperson, each should lock the main switch with a
personal lock and retain the key.
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Fork lift trucks:
Powered trucks require safeguards for the operator's protection and

for the safety of other workers. Site Management must establish
guidelines for the operation, maintenance, and inspection of this
equipment.
Common types of industrial trucks include lift trucks, straddle trucks,

crane trucks, tractors and trailers, motorised hand trucks, and
automated guided vehicles.
Power source, operator position, or means of engaging the load

classifies powered industrial trucks.
Rider controlled trucks, such as the lift truck, are designed to be

controlled by a driver who rides on the truck.
Motorised hand trucks and electronically controlled or automated

guided vehicles can be controlled from the outside.
Factors to consider in purchasing/hiring trucks include work site

conditions, operator comfort, backup systems, and safety features
such as seat belts and wraparound seats.
Safeguards common to all trucks include guarded lifts and tires,

horns or other warning devices, reinforced platforms, and nameplate
with rated capacity.
Standards specify certain hazardous locations, Classes 1 through Ill,

in which various types of trucks should not be used unless they
comply with requirements or are officially approved.
All trucks should carry fire extinguishers regardless of their location

classification.
Lift trucks should have overhead guards designed to prevent injury.
Operators should realise that lift trucks are generally steered by the
rear wheels, handle more easily when loaded, are used in reverse as
often as forward, and are often steered with only one hand. Drivers
must be shown how to handle various types of loads, to drive on
different gradients, to load and unload the truck properly, and to
stack pallets safely.
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Straddle trucks present a special problem because the operator sit

so high off the ground they cannot see directly in front or behind
them.
Horns, red flags, or other warning devices should be used to protect

pedestrians.
Crane trucks should be driven at the lowest possible speed when

carrying a load to maintain its balance.
Some useful tips for drivers for safe operation of the fork lift
truck:
• When you back out of an aisle, remember to allow enough room

for forks to clear the sides before starting the turn.
• If you leave your forklift unattended for any reason. always
lower the mast completely, turn off the engine and set the
brake
• Some policies may state that if you are closer than 25 feet or
maintain
• Visual contact with the forklift, you may leave the engine
running.
• Practice and concentration on your work are the keys to
becoming a successful operator. Keep in mind that you put
yourself and your
• Co-workers in danger when you do not follow safe operating
procedures.
• A professional forklift driver will make sure that equipment is in
good condition and will practice safe operating techniques.
Points to remember about inspecting and operating a forklift

include:
Pre-Use Inspections:
- Always inspect the forklift before you start work. ( mast for
broken weld, proper lubrication of roller tracks and chain, forks
properly placed/not cracked, hydraulic fluid level and leakage)
- Inspecting the Power Source:
- Finding The Rated Capacity;
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Safety Tips:
• Never lift load while moving

• Stop before you raise mast.
• Be sure that load sits squarely on stack, or it could tip over.
Driving With A Load:
Always travel with load tilted slightly back, keep load at proper
height. Drive slow. If you can't see, drive in reverse.
Safe Steering: Drive slowly, slow for turns; stay wide when turning
into aisles.
There are many floor surfaces a forklift must operate on.

These Suggestions will help to ensure safe operation:
Slippery floors - Slow speed, brake carefully, and avoid tight turns.
Overhead clearance - Be aware of clearance, mast and overhead

guard height.
Tight spaces - Move empty forks to one side, steer to maximise

turning angles.
Heavy traffic areas - Set loads carefully, maintain safe speed, and
use horn to alert others.
Loading docks - Check for bridge security, avoid acceleration.
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8.1 Work over water:
Falling into water and being drowned or carried away by currents is

an ever-present danger when working over or adjacent to water.
Rules 86 & 87 of “ THE BUILDING AND OTHER CONSTRUCTION

WORKERS (REGULATION OF EMPLOYMENT AND CONDITIONS OF
SERVICE) CENTRAL RULES, 1998 ” give the requirements when
workers are allowed to work on or adjacent to water.
Even though the worker may be a good swimmer, the following

precautions should always be followed:
! Make sure that the working platform is secure and has no tripping
hazards such as tools, wire, timber or bricks. Surfaces soon become
slippery and should be treated immediately by cleaning, gritting or
applying industrial salt or sand.
! Check that access ladders guard-rails and toe boards are firmly fixed in
position.
! Wear a safety helmet at all times - if you are struck on the head and
fall into water you are at special risk.
! Wear a life jacket, and ensure that it is properly fastened.
! Use any safety nets or safety harness provided.
! Check that lifebuoys fitted with lifelines are ready to hand for
immediate use.
! Make sure that there is a safety boat and that it is manned while you
are working above water - if over tidal water or a fast-flowing river, it
must have a motor with a self-starting device Ensure that you know the
routine for raising the alarm and for rescue drill.
! Needs of both workers and supervisors.
Critical Jobs 1
8.2. Confined Spaces:
If you are one of the workers who work in confined spaces each year, you
know your job is dangerous.
Serious injury or death in a confined space can be result of:
" Asphyxiation
" Engulfment
" Electric shock
" Fall & heat stress
NOISH defines a confined space as
A space that by design has limited openings for entryand exit;

Unfavorable natural ventilation which could contain or produce dangerous
air contaminants,
&
Which is not intended for continuous human occupancy.
Class A spaces are those that present situation which are immediately
dangerous to lift or health. These include spaces that are either deficient in
oxygen or certain explosive, flammable or toxic atmospheres.
Class B spaces do not present an immediate threat to life or health:
however, they have the potential for causing injury or illness if protective
measures are not used.
Class C spaces are those where any hazards posed are so insignificant
that no special work practices or procedures are required.
Some examples of Confined Spaces
TANK SILO PIPELINE
Critical Jobs 2
Typical reasons for confined space entry:

# Inspection of physical integrity and process equipment.
# Maintenance such as abrasive blasting and application of surface
coatings.
# Tappings, coating, wrapping and testing of underground sewage,
petroleum, steam and water piping system.
# Installing, inspecting, repairing and replacing valves, piping, pumps,
motors, etc. in below ground pits and vaults.
# Cleaning to remove sludge and other waste materials.
# Repair, including welding and adjustments to mechanical equipment.
# Adjusting and aligning mechanical devices and components.
# Checking and reading meters, gauges, dials, charts and other
indicators.
# Installing, splicing, repairing and inspecting electric and telephone
cables.
# Rescue of workers who are injured or overcome inside the space.
Permit - required Confined Space

Permit required confined space has one or more of the following
characteristics:
# Contains or has potential to contain a hazardous atmosphere.
# Contains a material that has the potential for engulfing an entrant.
# Has an internal configuration such that the entrant could be trapped or
asphyxiated by inwardly converging walls or by a floor which slopes
downward and tapers to a smaller cross-section.
# Contains any other recognized serious safety or health hazard.
Confined Space Hazards
1. Oxygen deficient atmospheres are atmospheres which contain

less than 19.5% v/v oxygen.
2. Toxic vapors and gases which exceed their PEL(Permissible
Exposure Limit) should be considered Immediately Dangerous to
Life or Health. Conditions may result in acute or immediately
severe health effects.
3. Flammable or Combustible Atmospheres are hose in which
flammable or combustible vapors/gases are equal to or greater
than 10% LEL (Lower Explosive Limit).
Critical Jobs 3
Confined Space hazards:
A. Atmospheric Hazards
# Oxygen deficiency atmospheres.
# Oxygen enriched atmospheres.
# Flammable atmospheres
# “Toxic” or irritating atmospheres.
B. Physical Hazards:
# Unexpected movement of machinery.
# Electrocution by electrically energized conductors.
# Fluids: liquids, powders and gases.
# Heat stress, Thermal condition: hot or cold.
# Engulfment by finely divided material or liquid.
# Ionizing and non-ionizing radiation.
# Contact with corrosive substances.
The PERMIT Space Programme
Steps to control the hazards of permit spaces:

# Identify all permit spaces in your workplace.
# Reduce employee risk around permit spaces with signs or
training.
# Prevent unauthorised employee entry in permit space
Program.
# Develop & implement a written permit space program.
# Document procedures establishing a non-permit space.
# Re-evaluate spaces when conditions change.
# Make special arrangements with contractors who may enter
permit spaces.
# Supply safety and personal protective equipment.
Elements of Confined Space Entry Programme:
# Procedures for identifying hazards associated with entry.

# Procedures, method and practices used to control confined space
hazards.
# A written permit system.
Critical Jobs 4
# Specialized equipment, such as air sampling struments,

ventilation equipment, rescue gear, Personal Protective
Equipment, etc. required for entry.
# Designation of employees who have an active role in the entry,
e.g., authorised entrants, attendants, and entry supervisor.
# Provision for testing and evaluating the space to ensure that
conditions are suitable for entry.
# Coordination of contractor activities.
# Emergency response procedures, including provision forrescue
equipment and an attendant.
# Employee training and information.
# Annual program review to assure continued effectiveness.
Critical Jobs 5
THE WORK BEING DONE CAN CAUSE CONDITIONS IN A

CONFINED SPACE TO BECOME MORE HAZARDOUS:
# Hotwork uses up oxygen and can release

hazardous materials.
# Sanding, scraping and loosening residue can
stir up hazardous materials.
# Workers bring hazardous materials, such as
solvents, paints into the permit space.
# Work outside a permit space can produce
harmful vapors that collect inside.
Preparation of the Permit Space:
# All departments likely to be affected by service

interruption must be noticed.
# Post signs and put up barriers to protect entrants
from vehicle traffic and pedestrians from falling
into the space.
# Blind or disconnect and cap all input lines,
that no hazardous materials can enter the space.
# When ventilation is needed, begin long enough
in advance so that the air will be safe before
anyone enters. Verify breathing safety by air testing.
# Empty the space of any materials that may
be hazardous. If necessary, clean, purge or
inert hazardous residue in the space.
# Make sure no hazardous energy can be released.
Follow your company’s lockout / tagout rules.
# Assignment and training of entry supervisor,
attendant and entrants is required to comply
with the employer’s Permit space Plan.
# Attach completed Hotwork permit, if required, to Confined Space
# Entry Permit.
# Add emergency contact telephone numbers.
Critical Jobs 6
Equipment required for entry and work:

# Appropriate personal protective equipment, such as hard hats, face
shields and encapsulated suits must be made available at the site.
# Decide whether respirators and portable air monitors are required and
which types match the hazard.
# Choose and list devices for communication. Test it before entry.
# List any special light sources, spark-proof tools and other electrical
equipment that must be on hand before entry begins.
# Make sure this equipment is intrinsically safe and in good condition.
# List any measures needed to guard against shock, such as ground-fault
circuit interrupters.
# List any measures needed to guard against shock, such as ground-fault
circuit interrupters.
# List devices such as ladders, boatswain’s chairs and work platforms.
Test this equipment before entry begins.
Permit Authorisation:
# The entry supervisor fills up the confine space entry work permit.
# After verifying that acceptable entry conditions exist, the entry
supervisor signs and dates the permit.
# ONLY THEN workers are allowed to enter the permit space.
General Entry Work Practices in Confined Spaces:
! The air in the vessel must be tested for oxygen and for flammable and
toxic gases before entry
! Lifelines and safety harness must be used by all the persons entering in
the confined spaces.
! A person must also be stationed outside the vessel in a position to
handle the lifeline and to summon assistance in case of an emergency.
! Self-contained breathing apparatus must be kept ready for emergency.
! All the inlet of the vessel that could injure the entrant if operated
unexpectedly must be blinded or locked in the“Safe” position.
Welding & Gas cutting in confined Spaces:
# Minimum general ventilation rate of 2000 cubic feet per minute per
welder be maintained in confined spaces.
Critical Jobs 7
# If local exhaust is used, the capture velocity at the point of work must
be at least 100 feet per minute.
# Local exhaust or air-supplied respirators must be provided if welding,
cutting or heating is performed on beryllium -, lead -, cadmium - or
mercury -coated base metals.
# Welding machines and compressed gas cylinders must be kept outside
the confined spaces.
# When work stops for a prolonged period of time, electrodes must be
removed from their holders and gas flow to torches must be shut off
from outside the space.
Excavations, Trenching and Shoring:
# Special precautions must be taken when employees enter trenches

deeper then four feet that are dug in locations where atmospheric
hazards may be present.
# These locations include places such as landfills, hazardous waste sites,

chemical plants, refineries and underground storage tank removal
projects.
Critical Jobs 8
Physiological effects of Oxygen at different levels.
Oxygen enriched atmosphere.
Normal air oxygen level.
Minimum safe entry level.

Disturbed respiration, emotional sets,
abnormal fatigue on exertion, flames
are extinguished.
Increased respiration, heart

coordination may be disturbed,
some euphoria, possible headache.
Nausea and vomiting, inability to

move freely, possible unconsciousness,
possible collapse while remaining
conscious but helpless.
Gasping respiration, Respiration

stops, followed by cardiac arrest,
death in minutes.
Causes of Oxygen Deficiency
In confined spaces ambient oxygen being,

# Consumed by industrial processes like welding, torch cutting and
blazing, fuel fired space heaters.
# Consumed by chemical reactions like oxidation (Rusting and naturally
occurring fermentation)
# Displaced by inert gases like argon, carbon dioxide and nitrogen
# Adsorbed by porous surfaces like activated charcoal.
Critical Jobs 9
OR
If make-up air is inadequate, Carbon monoxide produced by inefficient

combustion, which combines with hemoglobin about 200 times more
easily than oxygen.
Oxygen Enriched Atmosphere
# Permit flammable gases and vapors to ignite over a much wider range
of concentrations than is possible in ordinary air.
# Alters the burning characteristics of many materials, making them
both easier to ignite and faster burning once ignited.
Sources
1. Oxygen used to ventilate tank during repair.

2. Compressed oxygen used to dislodge welding slag.
3. Leaking welding oxygen lines in barge wing tank.
Critical Jobs 10
9. Welding and Gas Cutting:
Introduction:
The purpose of welding is to join metal parts. All welding process requires
heat and sometimes other substances to produce the weld. Because high
heat is used to make the weld, a number of by-products results from the
process, including fumes and gases that can be a serious health hazard to
workers. Safety hazards are also associated with welding, such as the
potential for fire or explosion and injuries form arc radiation, electrical
shock, or material handling.
Definitions used in this chapter are those of the American Welding
Society. “Welder” and “Welder Operator” refer to the individual only. The
machine performing the welding operation is referred to as the “Welding
machine”. Equipment supplying current for electric welding is called either
a “Welding generator” or a “Welding transformer”.
Hazards:
1. Health Hazards:
The most significant health hazard in the welding process is the

generation of fumes and gases. The amount and type of fumes
and gases involved will depend on the welding process; the base
material, the filler material, and the shielding gas, if any. The
toxicity of the contaminants depends primarily upon their
concentrations, and upon the physiological responses of the
human body. Sampling by an industrial hygienist or other
qualified person may be necessary to fully identify the fumes and
gases actually being given off in a specific operation.
(a) Toxic Gases:

Exposure to various toxic gases generated during welding may
produce one or more of the following effects:
• Inflammation of the lugs (chemical pneumonitis)
• Pulmonary edema (swelling and accumulation of fluids)
• Emphysema (loss of elasticity of the lungs; very small
percentage of emphysema caused by occupational
exposure)
• Chronic bronchitis
Welding and Gas Cutting 1

• Asphyxiation
The major toxic gases associated with welding are classified as
primary pulmonary and nonpulmonary.
(b) Cleaning Compounds used

Because of their chemical properties, cleaning compounds can
create health hazards if improperly mixed. They often require
special ventilation precautions. Follow the manufacturer's
instructions.
(c) Chlorinated Hydrocarbons

Degreasing operations often employ chlorinated solvents that can
decompose to toxic phosgene gas in the presence of the
ultraviolet radiation emitted by the welding arc.
(d) Asbestos
If welding or cutting involves asbestos, the regulations of the
agency having authority must be consulted before beginning the
job. Asbestos can produce fibrosis and lung and other cancers.
2. Safety Hazards
(a) Fire Protection
Because portable welding and cutting equipment creates special

fire hazards, it should be used in a permanent welding and
cutting location that can be designed to provide maximum safety
and fire protection. Otherwise, the welding and cutting site
should be inspected to determine what fire protection equipment
is necessary.
It is advisable, particularly in hazardous locations, to require "Hot

work" permits issued by the welding supervisor, a member of the
plant fire department, or some other qualified person before
welding or cutting operations are started. Specifications for hot
work permits are outlined in the annexe.
(b) Floors and Combustible Materials

Where welding or cutting must be done near combustible
materials, special precautions are necessary to prevent sparks or

hot slag from reaching such material and starting fires. If the
work itself cannot be moved, the exposed combustible material
should, if possible, be moved a safe distance away. Otherwise, it
should be covered with sheet metal. Spray booths and ducts
should be cleaned to remove combustible deposits. Before
welding or cutting is started, wood floors should be swept clean
and, preferably, covered with metal or other non-combustible
material where sparks or hot metal may fall. In some cases, it is
advisable to wet down the floor, though the wet floor increases
the shock hazard to electric (arc and resistance) welders and
necessitates special protection for them.
If gas welding or oxygen cutting is done inside a booth provided

for arc welding, the gas cylinders should be placed in an upright
and secured position away from sparks to prevent contact with
the flame or heat.
Hot metal or slag should not be allowed to fall through cracks in

the floor or other openings, nor into machine tool pits. Cracks or
holes in walls open doorways, and open or broken windows
should be covered with sheet metal guards. Because hot slag
may roll along the floor, it is important that no openings exist
between the curtain and the floor. Similar protection should be
installed for wall openings through which hot metal or slag may
enter when welding or cutting operations are conducted on the
outside of the building.
If it is necessary to weld or cut close to wood construction, or

near combustible material that cannot be removed or protected,
a fire hose, water pump tank extinguisher, or fire pails should be
conveniently located. Portable extinguishers for specific
protection against Class B and C fires should also be provided.
Pails of limestone dust or sand may be useful. It is good practice
to provide a fire extinguisher, either dry chemical, multipurpose
chemical, or carbon dioxide, for each welder.
A fire watcher equipped with a suitable fire extinguisher should

be stationed at or near welding or cutting operations conducted in
hazardous locations to see that sparks do not lodge in floor
cracks or pass through floor or wall openings. The fire watch

should be continued for at least 30 minutes after the job is

completed to make sure that smoldering fires have not been
started.
Hazardous Locations
Welding and cutting operations should not be permitted in or near rooms

containing flammable or combustible vapours, liquids, or dusts. Nor
should they be permitted on or inside closed tanks or other containers
that have held such materials until all fire and explosion hazards have
been eliminated. All of the surrounding premises should be thoroughly
ventilated, and frequent gas testing provided. Sufficient draft should be
maintained to prevent accumulation of explosive concentrations. Local
exhaust equipment should be provided for removal of hazardous gases,
vapours, and fumes (present in the surroundings or generated by the
welding or cutting operations) that ventilation falls to dispel.
1. Drums, Tanks, and Closed Containers
Closed containers that have held flammable liquids or other combustibles

should be thoroughly cleaned before welding or cutting. If the containers
cannot be removed for standard cleaning procedures, two other practices
are sometimes followed: (1) the containers are purged with an inert gas
(Figure 19-1), or (2) they are filled with water to within an inch or two of
the place where the work is to be done and a vent is left open. Either of
these measures may also be used
The accepted method for preparing tanks and drums for welding is:
1. Remove all sources of ignition (open flames, unguarded electric lights,

etc.) from the vicinity of the drum to be cleaned.
2. Remove the bung w' h a special long-handled wrench.
3. Examine the inside for rags, waste, or other debris that might interfere
with free draining. Use a portable electric hand lamp that is listed for
hazardous location, or an electric extension lamp protected by a guard
of spark resistant material.
4. Place the drums on a steam rack with the bungholes at the lowest
possible point, and let the drums drain for some minutes.
5. Steam the drums for at least 10 minutes. Drums that have contained
shellac, turpentine, or similar materials require longer steaming.

6. Remove the drums from the steaming rack, and fill drum part way
with caustic soda or soda ash solution. The drums for at least 5
minutes. Light hammering with a wood mallet will help to loosen
scale.
7. Thoroughly flush the drums for at least 5 minutes boiling water. A
water spray nozzle placed 6 to 8 in to 20 cm) inside the drum can be
used. Drums should placed so that water can drain out the
8. Wash down the outside of the drum with a hose stream of hot water.
9. Dry the drum thoroughly by circulating warm air throughout the
inside.
10.Thoroughly inspect the interior of the drum, using a light that is
listed for hazardous locations, and a small mirror. If it is not clean,
repeat the cleaning process.
11. Test the container for the presence of flammable vapours with a
combustible gas indicator. Test for toxic contaminants and for oxygen
sufficiency or enrichment if personnel are to enter.
12. Make similar tests just before welding repair operations are
performed. If operations extend over an appreciable period of time,
make repeated tests.
Precautions for employee protection during container cleaning operations

include the following suggestions:
• Wear head and eye protection, rubber gloves, boots, and aprons
when handling steam, hot water, and caustic solutions. When
handling dry caustic soda or soda ash, wear approved respiratory
protective equipment, long sleeves, and gloves.
• To handle hot drums, wear suitable hand pads or gloves. Steam
irons or other hot surfaces that may be touched should be insulated
or otherwise guarded.
• Dispose of residue in a safe manner. In each instance, the method
of disposal should be checked for hazards.
• If a vessel must be entered, wear respiratory protective equipment
approved for the exposure and a safety harness with attached
lifeline tended by a helper who is similarly equipped and stationed
outside the vessel. Rescue procedures should be tested for
adequacy before beginning.
Refer to Material Safety Data Sheets provided by the manufacturer to

identify any of the materials listed above that may be contained in the
consumable. Whenever these materials are encountered as

designated constituents in welding, brazing, or cutting operations,

ventilation precautions must be taken to assure the level of
contaminants in the atmosphere is below the limits allowed for human
exposure. Unless atmospheric tests under the most adverse
conditions have established that exposure is within acceptable
concentrations, the following precautions need to be observed.
Ventilation
Natural. Natural ventilation is acceptable for welding, cutting, and

related processes where the necessary precautions are taken to keep
the welder's breathing zone away from the plume and where sampling of
the atmosphere shows that concentrations of contaminants are below
the levels given above. Taking air samples at the breathing zones of the
personnel involved is the only way to assure that airborne contaminant
levels are within the allowable limits.
Natural ventilation often meets the standards if the necessary

precautions are taken to keep the welder's breathing zone away from
the plume and all of the following specifications are met:
• Space of more than 10,000 ft3 (284 m-3) per welder is provided
• Ceiling height is more than 16 ft (5 m)
• Welding is not done in a confined space
• Welding space refers to a building or an enclosed room in a building,
not a welding booth or screened area that is used to provide
protection from welding radiation; nor does the welding space
contain partitions, balconies, or other structural barriers that
obstruct cross-ventilation m materials covered above are not
present as deliberate constituents.
Mechanical : Mechanical ventilation includes local exhaust, local forced,

and general area mechanical air movement. Local exhaust
ventilation is preferred. It means fixed or movable exhaust hoods
placed as near as practical to the work and able to maintain a capture
velocity sufficient to keep airborne contaminants below the limits.
Local forced ventilation means a local air-moving system (such as a

fan) placed so that it moves the air at right angles (90 degrees) to the
welder (across the welder's face). It should produce an approximate

velocity of 100 ft per min (30 m per min), and be maintained for a
distance 'Of approximately 2'ft (0.6 m) directly above the work area.
Precautions must be taken to ensure that contaminants are not
dispersed to other work areas.
General area mechanical ventilation includes roof exhaust fans, wall

exhaust fans, and similar large area air movers. General mechanical
ventilation is not usually satisfactory. It is often helpful, however, when
used in addition to local ventilation. General mechanical ventilation may
be necessary ventilation to maintain the general background level of
airborne contaminants below the levels referred to or to prevent the
accumulation of explosive gas mixtures.

Handling and storage of cylinders:
Precautions in handling of gas cylinders :
1. Do not remove or change numbers or marks stamped on cylinders.
2. Because of their shape, smooth surface and weight, cylinders are

difficult to carry by hand, carry it with some Mechanical Aid.
3. Protect cylinders from cuts or abrasions.
4. Do not lift compressed gas cylinders with an electro-magnet. Where

cylinders must be handled by a crane or derrick, as on construction
jobs, carry them in a cradle or similar device and take extreme care
that they are not dropped. Do not use slings.
5. Do not drop cylinders or let them strike each other violently.
6. Do not use cylinders for rollers, supports, or any purpose other than to
contain gas.
7. Do not tamper with safety devices in valves on cylinders.
8. When in doubt about the proper handling of compressed gas cylinders

or its contents, consult the supplier of the gas.
9. When empty cylinders are to be returned to the vendor, mark them

EMPTY with chalk. Close the valves and replace the valve protection
caps.
10. Load cylinders to be transported to allow as little movement as

possible. Secure them to prevent violent contact or up setting.
11. Always consider cylinders as full and handle them with corresponding
care. Accidents have resulted when containers under partial pressure
were thought to be empty.
12. The fusible safety plugs on acetylene cylinders melt at about the
boiling point of water. If an outlet valve becomes clogged with ice or
frozen, it should be thawed with warm (not boiling) water, applied
only to the valve. A flame should never be used.

13. Cylinders together with their valves and other fittings and other
fittings and the identification colours under these rules shall always
be maintained in good condition.
14. No oil similar lubricant shall be used on any valves or other fittings of
any cylinder.
15. Every cylinder containing compressed gas shall have valve securely
closed so as to prevent leakage.
16. If a leak in the valve can not be rectified by lightening the gland nut
or the spindle, the cylinder shall be removed to an open space where
it is least dangerous to life and properly and the filler shall be
informed.
17. As per rule 9 (2) of gas cylinder rules,1981.
Rule 9(2) of gas cylinder rules, 1981 prescribes 4 warning in the following
terms are attached to every cylinder containing permanent or liquefiable
gas, namely:
“WARNING”
Gas Cylinder Rules, 1981
(i) The colour of the cylinder should not be changed.

(ii) The cylinder should not be filled with any gas other than the one it
contains.
(iii) No flammable material should be stored in the immediate vicinity of
the cylinder or in the same room in which it is kept.
(iv) No oil or similar lubricant should be used on the valves or other
fittings of this cylinder.
(v) The cylinders should be periodically tested and inspected and the
record of the same should be maintained.
COLOUR CODING:
The cylinders should be painted as per the Indian Standards for easy
identification. To prevent inter change of fittings, the valve out lines are
screwed left and right respectively.

Precaution in Storage of Cylinders
1. Store cylinders in a safe, dry, well - ventilated place prepared and

reserved for the purpose.
2. Flammable substances, such as oil and volatile liquids, should not be

stored in the same area.
3. Never store cylinders near elevators, gangways, stairwells or other

places where they can be knocked down or damaged.
4. Never store oxygen cylinder close to cylinders containing flammable

gases.
5. Store acetylene and liquefied fuel gas cylinders with the valve end up.
6. Acetylene storage rooms and buildings must be well ventilated, and

open flames must be prohibited.
7. Cylinders should be stored on a level floor.
8. To prevent rusting, cylinders stored in the open should be protected

from contact with the ground and against extremes of weather -
accumulations of ice and snow in winter and continuous direct rays of
the sun in summer.
9. Cylinder storage should be planned so those cylinders will be used in

the order in which they are received.
10. Cylinders are not designed for temperatures in excess of 130 F.

Accordingly, they should not be stored near sources of heat, such as
radiators or furnaces, or near highly flammable substances like
gasoline.
11. Cylinder storage should be planned so those cylinders will be used in

the order in which they are received from the supplier.
12. Never permit cylinder to have contact with direct flame or electric
arc.

13. For storage of gas cylinders flammable storage rooms for cylinders
containing flammable gases should be well ventilated to prevent the
accumulation of explosive concentrations of gas.
14. Never allow cylinders to come into contact with electrical apparatus
or live wires, since arcing may be set up which will heat or damage
the cylinders.
15. Never strike an arc or tap an electrode on a gas cylinder whether full
or empty.
16. Oil or grease must under no circumstances be allowed to come in

contact with one another.
17. Never transport cylinders with the regulators and hose attached
unless a proper trolley or carrier is used. When transporting by a
trolley the cylinder valve must be shut before the cylinder is moved
from place to place.
18. If an acetylene cylinder becomes hot or fires internally due to

external fire or uses of faulty equipment, close the valve, disconnect
the regulator (if possible) remove the cylinder into the open, the
open the valve fully to allow the gas to escape freely. Meantime,
apply water to cylinder body from a hose or immerse the cylinder in
a tank of water and inform the supplier immediately.
Care in the Use of Gas Cutting Set
1. Before attaching a regulator to the cylinder it is necessary to ‘Shift’

the valve in order to remove foreign particles or moisture from the
valve seat. Care should be taken to see that the regulator chosen be
the correct one to use for the gas contained in the cylinder.
2. Before fixing a regulator on to a full cylinder, always release the

adjusting screw for regulating the pressure output, otherwise there is
a risk of damage to the regulator.
3. Make sure that the threads on regulators and other auxiliary

equipment are the same as those on the cylinder valve outlets.

4. Leaks of gas are dangerous. Check all connections regularly faulty or

leaky equipment should be changed without delay.
5. There are two types of blowpipes in common use i.e. low pressure and
high pressure. Remember, a low pressure blow pipe may be used on a
high pressure system, but under no circumstance, can a high pressure
blow pipe be used on a low pressure system.
6. Inspect rubber hose periodically to see that it is free from cuts, cracks,
burns and worn places and arranges it so that it can not be cut by
contact with sharp edges or corners, falling metal, sparks or the blow
pipe flame.
7. Use red hoses for acetylene and to other fuel gases and black for
oxygen and be careful to see that they are never inter changed.
8. Use hoses of equal length and do not coil any surplus hose around
regulators or cylinders.
9. Nozzle tips should be kept clean as otherwise distortion of flames and

back-fire may result. Never poke a nozzle orifice with a steel wire.
10. Cylinders should not be used to support the work, nor should the
blow pipe flame be allowed to come in contact with the cylinders. The
blow pipe when alight should not be hung on the cylinder or on the
regulator.
11. To blow out dust or dirt that otherwise might enter the regulator,
“crack” the discharge valve on the cylinder by opening it slightly for
an instant and the close it. On a fuel gas cylinder, first see that no
open flame or other source of ignition is near; otherwise, the gas
may ignite at the valve.
12. Connect the regulator to the outlet valve on the cylinder. Be sure the
regulator inlet threads match the cylinder valve outlet threads. Never
connect an oxygen regulator to a cylinder containing fuel gas, or vice
versa. Don’t force connections which do not fit. Be sure that the
connections between the regulars and cylinder valves are gas-light.

13. Release the pressure adjusting screw on the regulator to its limit –
turn it counter - clockwise until it is loose.
14. Open the cylinder valve slightly to let the hand on the high pressure
gauges move up slowly. On an oxygen cylinder gradually open the
cylinder valve to its full limit, but
Care in the Use Arc Welding Transformer / Generator
1. Provide switch fuse adjacent to the equipment in order that it may be

isolated from supply main, if necessary.
2. Both portable and stationary equipment must be double earth with 8

SWGI wire. In addition, the work must, of course, be earthed.
3. On the output (i.e. Secondary) side of transformer, cables of the

correct type and capacity tied with the appropriate connectors / lugs.
4. In service, the welding operator should check all external connections

daily and report any weakness, defects etc.
5. Ensure that all connections are clean and tight, that they are correctly
made, that the correct types and sizes of cables, earthing clamps,
electrode holders, cable connectors are being used.
6. Periodically clean and tight the jaws of electrode holder to prevent

overheating.
7. Much of the heat generated in a holder is the result of poor electrical

contact at the jaws holding the electrode, and a spring or other grips
ensures a uniform pressure. Use good quality insulated electrode
holder.

Personal Protection for Welders
(A) Protective clothing for the body
Wear leather apron to protect his body and clothing from the heat of
the work, to prevent burns which can be caused by small globules of
metal falling on his thigh and legs, and in gas shielded ultra-violet
radiation and ozone on clothing.
1. Flame - resistant gauntlet gloves, except on very light work.
2. Aprons of leather, asbestos or other flame - resistant material to

withstand radiated heat and sparks.
3. For heavy work, fire-resistant leggings, high boots or similar

protection.
4. Safety shoes, wherever heavy objects are handled, Low - cut

shoes with unprotected tops should not be used because of the
spark hazard.
5. For overhead work, capes or shoulder covers of leather or other

suitable
(B) Gloves
To protect the hands against heat, spatter and radiation, gloves must
be worn, and these should be of the leather gauntlet type with
canvas or leather cuffs, as specified in IS :
(C) Head protection
* When molten metal or hot particles are emitted during welding, the
welder should wear a leather apron to protect his clothing.
In the case of cutting operation it is advisable to wear asbestos -

cloth or leather spats so as to prevent hot particles from falling into
the boots or shoes.

General Safety Protections
1. Sparks from welding and particularly from gas cutting can travel a
considerable distance.
2. Fire extinguishers and sand should be readily accessible and water

should be used to flood the floor where no other protection is possible.
3. Do not weld out tanks or vessels which may have contained petrol,
oils, spirits or any other inflammable or explosive material without
make it safe. They should be washed out thoroughly with caustic soda
or carbon tetrachloride and then with water. If possible pass steam
also.
4. When cutting or welding inside boilers or other confined spaces, gas

cylinders should always keep gas cylinder outside and take special care
to make sure that the hose is in good condition. Have a pail of water
and fire extinguisher at hand and have an assistant outside to control
the gas supply and to give any necessary help.
5. Wear an approved respirator when paint burning, cutting, welding or

flame cleaning on painted galvanized plate for an extended time or in
a badly ventilated place
6. Never do welding or cutting on a concrete floor, because when heated,

a portion of the concrete may spell and fly with possible injury to the
operator.
7. If welding or cutting is performed in a confined space and an operator

must enter through a manhole or other small opening some means
should be provided for quickly removing him in ease of an emergency.
8. Use a spark lighter and not a match-stick to light up a flame.
9. Suitable fire-extinguishing apparatus should always be ready to hand

and, if the working condition are such that a fire risk is present, a
responsible person should keep the site under observation for at least
half an hour after completion of the work, in order to watch for and

deal with any outbreak of fire. It is not un - common for a fire to

smolder for many hours before breaking out.
10. It is the operator’s duty to adequately protect his own clothing and
person from sparks, flying particles of incandescent metal or slag.
Never wear oily or greasy clothing of any kind.
11. For work at more than 5 ft. above the floor or ground, use a
platform with railings, or a safety belt and lifeline.
12. Wear respiratory protection as needed and a safety harness with

attached lifeline for work in confined spaces, such as tanks and
pressure vessels. The lifeline should be tended by a similar equipped
helper whose duty is to observe the welder or cutter and effect
rescue in emergency.
13. Take special precautions if welding or cutting in a confined space is

stopped for some time Disconnect the power on arc welding or
cutting unit and remove the electrode from the holder. Turn off the
torch valves on gas welding or cutting units, shut off the gas supply
at a point outside the confined area, if possible, remove the torch
and hose from the area.
14. After welding, or cutting is completed, mark hot metal or post a

warning sign to keep workers away from heated surfaces.
15. Follow safe house keeping principles, Do n’t throw electrode or rod
stubs on the floor - discard them in the proper waste container. Keep
tools and other tripping hazards off the floor - put them in a safe
storage area.
16. Obtain a written permit before using portable cutting or welding

equipment any where.
17. Before starting, sweep floors clean, wet down wooden floors, or cover
them with sheet metal or equivalent. In outside work, don’t let
sparks enter doors or windows.

18. Move combustible material 13 meters away; cover what can’t be

moved with asbestos curtains or sheet metal, carefully and
completely.
19. Station extra men with hose, extinguishers, or fire pails to watch
sparks and see that they do not start fire.
20. After completion, watch scene of work half-an-hour for smoldering

fires, and inspect adjoining rooms and floors above and below.
21. Don’t use the equipment near flammable liquids, or on closed tanks
which have held flammable liquids or other combustibles. Remove
inside deposits before working on ducts.
22. Keep cutting and welding equipment in good condition. Carefully

follow manufacturer’s instructions for use and maintenance.
23. See that the fire service should be called at the first sign of fire.
24. Cutting and welding operators, and every other person concerned,
shall be instructed to watch for and be ready immediately to
extinguish any fire that may occur and know how to transmit a call to
the nearest fire station.
25. Ample supply of dry sand in suitable containers shall be provided.
26. Suitable extinguishers conforming to IS : 1648 - 1961 shall be

available for immediate use.
27. Hoses connected to an effective water supply, or where such supply

is not available an ample supply of water in suitable containers shall
be available.

ANNEXURE
GAS CUTTING & WELDING
CHECK LIST
Sr. Description Observation Action /

No. Yes / No Comments
1. Is the welding cables routed properly above

the ground?
2. Is welding equipment installed in an

elevated position & operating?
3. Is there any system of maintaining the

machines--- with records?
4. Is the welding cables inspected periodically?
5. Is there any shed / cover for the welding

machine?
6. Are operators / welders qualified?
7. Whether proper safety appliances are given

and used.
8. Are the flammable materials removed /

covered?
9. Are clamps clips on hoses conforms to BIS

& physical condition is O.K.?
10. Are hose conform to BIS Specification?
11. Is physical condition of hose O.K?
12. Are hoses stored after us in oil & grease

free place?

13. Are clamps and clips are used only for tying
up of welding hoses?
14. Is welding torch conforms to BIS

specification & nozzle is free from scale?
15. Is tip of welding torch nozzle is free from

scales?
16. Are colour code marking for flammable gas

cylinder and oxygen cylinder is done?
17. Are pressure gauges are provided & are in

working condition?
18. Are electrode holder used, conforms to BIS

specification?
19. Is current carrying capacity of electrode

holder is adequate?
20. Is physical condition of connecting lead is

O.K.?
21. Is crimping of lugs on welding lead O.K.?
22. Are gas cylinder kept vertically at safe

places?
23. Are hazardous (combustible)materials kept

beside / below gas cutting operation?
24. Are fire extinguishers / fire buckets

available near work place?
25. Are empty & filled cylinders stored

separately away from heat / sun light?

26. Are protective caps provided to all

cylinders?
27. Is tightness of connection of leads O.K?
28. Is distinctive double earthing of welding

generator / transformer done?
29. Is insulation resistance of welding

equipment checked?
30. Is separate cable for earthing taken for

welding return?
31. Is welder’s safety helmet provided to

welder?
32. Is fire blanket used to arrest welding

sparks?
33. Is hot used to arrest welding sparks?

10 HEALTH & HYGIENE
10.1 Work Environment:
The work environment at any construction site can cause discomfort to

the personnel working at the site due to any of the following reasons.
While elaborating these factors in the following chapters care has been
taken to give proper guidance either to completely eliminate them, if not,
to minimise their effect.
10.1.1 Noise and vibration:
Construction sites are noisy places. Excessive exposure to loud noise

can cause permanent damage to hearing of the workers. Noise at work
can cause stress, making it difficult to sleep. Very high levels of noise
caused, for example, by using cartridge tools can cause instantaneous
hearing damage.
The levels of noise produced in operations such as piling, tunnelling and

cleaning operations may be such that unprotected persons will exceed
their maximum recommended daily dose in a matter of seconds. Even a
few minutes' exposure every day to very noisy machines can be enough
to start permanent hearing damage. Loud noise can cause a temporary
partial loss of hearing, with recovery time varying from 15 minutes to
several days depending on the noise level. There may also be a
"ringing" in the ears which should be regarded as a warning - temporary
loss may become permanent with repeated exposure. Deafness
develops very gradually but cannot be cured once the damage has been
done.
Noise also makes it difficult to hear sounds that you need to hear such as
work signals and warning shouts.
THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION

OF EMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES,
1998 under Rule 34 indicate the requirement at the site for suppression
of excessive noise and vibration and also give under Schedule VI the
maximum permissible limit of exposure. This is given in Annexe 1.
Health and Hygiene 1

10.1.1.2 Noise control
There are several steps that can be taken on site to reduce noise:
• Check that exhaust outlets are fitted with silencers or mufflers, and do
not keep machinery running unnecessarily.
• Keep compressor motor covers closed when they are running.
• Check that concrete breaker mufflers and similar devices are securely
fitted.
• Check that machinery panels are secured and do not rattle.
• Ensure that sound-insulating screens are provided to reduce noise
from stationary plant, and that where practicable noisy machinery is
sited behind earth mounds or brick stacks to isolate or screen it as far
as possible.
10.1.1.2 Hearing protection:
If the workers are expected to work at or near a noisy machine, then
• The noise levels have to be measured, and those measurements are to

be recorded.
• If the level of the noise is high then appropriate earmuffs or ear plugs
should be provided for persons working near the source of such noise
and the worker should wear the ear plug until he completes his job.
The hearing protection should be kept clean and stored in a safe place
when not in use. The ear plug should be periodically examined and
should be replaced when found damaged.
10.1.1.3 Vibration:
Many noisy machines or hand-operated tools also transmit vibrations to

the body - pneumatic rock dribs or concrete breakers are common
examples. In this way they can injure muscles and joints, and affect
blood circulation causing what is known as "white finger disease". When
using these tools the worker should wear gloves, which help to cushion
the vibrations.

10.1.2 Illumination:
THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION OF

EMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES, 1998
under Rules 50 & 124 provides statutory illumination requirements for
passages and for excavation sites. The general requirements are given
below.
All parts of the site need to be properly lit by natural or artificial means
whenever work is going on. Site lighting is always necessary in those
areas short of natural light such as shafts and enclosed stairways.
Artificial lighting should be placed to avoid deep shadows - these may
conceal hazards which would be obvious in good light. Mounting of lights
should be as high as practicable to avoid glare, and lights should be
placed so that workers do not have to work in their own shadow.
Only robustly installed fittings which are well out of reach, such as
floodlighting, should be used and operated at full mains voltage.
Temporary electric lighting should be installed by trained electricians
using low-voltage equipment.
Ensure that the following are followed by workers:
• Do not interfere with the installation.
• Report any damaged insulation, on broken bulbs, lamp holders or

fittings.
• Make sure that cables are fastened well off the ground and do not let
cables or connections trail in wet conditions.
• Do not change bulbs.
10.1.3 Ventilation:
THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION OF

EMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES, 1998
under Rules 153, 154, 155, 156, 157, and 158 gives broad statutory
requirements for adequate and proper ventilation while undertaking
excavation and tunnelling works.
10.1.3.1 Hot weather

Workers on construction sites are often exposed to all weathers.

In tropical countries radiation from the sun, with high air temperatures
and humidity, increases fatigue from heavy work and causes heat stress
which may lead to heat exhaustion and heat stroke, the latter a medical
emergency, and to ill health. The effects of heat combined with physical
workload tend to accumulate.
Good welfare facilities are essential to health in hot climates, and the
suitable arrangement of working time is important. There should be:
• sufficient work breaks .. for moderately heavy or heavy work 50 per

cent or more rest time is essential;
• Rest areas should be away from workstations to cool off.,
• Adequate supply of clean, cool drinking-water should be provided and

the workers should be encouraged to drink as often as possible and in
small quantities .
• Washing facilities should be provided to allow the workers to bathe and

keep their work clothes clean.
10.1.3.2 Tips for Keeping the Body Cool:
- Keep out of direct sunlight as much as possible.

- Avoid unnecessary quick movements.
- Ensure that there is air circulation in operators' cabins.
- Avoid wearing tight clothes or those which prevent evaporation of
perspiration such as some plastic materials.
- Wear head protection.
- Take cool drinks regularly to replace moisture lost through
perspiration.
- Add salt to food or eat food that contains natural salt.
- Find a shady place for rest pauses.
10.1.3.3 Cold weather:

Cold is not just uncomfortable - it may affect health and judgement.

Although not a serious problem in tropical climates, it may nevertheless
be experienced at high altitudes and in the early morning at sites which
are well inland.
Some of the hazards of cold weather are as follows:
- There are more likely to be accidents if the temperature of the hands

falls below 150 Celsius, there is loss of concentration and co-
ordination.
- Workers repeatedly using vibratory tools such as rock drills may suffer
"white finger" syndrome involving sensory loss as a consequence of
cold.
- Prolonged exposure to temperatures around freezing may cause

frostbite or hypothermia.
- Wind can affect temperature. When the air temperature is 100 Celsius
and the wind speed is 32 km per hour, the temperature, so far as the
body is concerned, falls to freezing. This is called the chill factor.
Even where the temperature is above freezing point, a condition called
"immersion foot" can occur in wet conditions if the feet are not kept
dry.
10.1.3.4 How to keep warm
The following points should be considered when working in cold conditions
- Choose clothing which allows moisture to escape but does not allow
wind and rain to penetrate: waterproof clothing tends to prevent
evaporation of moisture.
- Avoid bulky clothes, as they hamper movement - a number of layers

of clothing are preferred.
- Hands and feet are particularly susceptible to cold.
- Use facilities for preparing hot meals and drinks, and for storing and
drying clothing.

Annexure -1
SCHEDULE-VI
PERMISSIBLE EXPOSURE IN CASES OF CONTINUOUS NOISE
(See rule 34)
Total time of exposure (continuous or a Sound level (in dBA) Pressure

number of short term exposoures) per
day (in hours)
(1) (2)
8 90
6 92
4 95
3 97
2 100
1½ 102
1 105
¾ 107
½ 110
¼ 115
Notes:- 1. No exposure in excess of 115 dBA is to be permitted.

2. For any period of exposure falling in between any figure and
the next higher or lower figure as indicated in column (1), the
permissible sound pressure level is to be determined by
extrapolation on a proportionate basis.

10.2 Personal Protective Equipment
Introduction:
Methods of controlling hazards in the workplace fall into three categories:

engineering controls, administrative controls, and personal protective
equipment (PPE). When engineering and administrative controls cannot
eliminate work hazards, PPE must be used to ensure worker health and
safaty. Generally speaking, however, it is the least desirable method of
controlling hazards because the hazard still is present in the workplace.
Once a company decides on the use of PPE, it should develop a company

policy on PPE usage for employees and visitors, select the proper
equipment for the existing hazards, implement a training program, and
enforce the use of PPE.
In selecting the proper equipment, the most important criterion Is the

degree of protection that a particular piece of equipment can provide
under various conditions. The Safety Equipment Institute helps to ensure
objective, fair testing and certification of PPE devices.
Workers should be encouraged to use PPE and should receive some type
of sanctions if they fail to wear the equipment. Companies can increase
compliance by enlisting the aid of line supervisors and managers, letting
employees have some choice in the type of equipment purchased, and
establishing a sound training program with consistent enforcement of all
rules and regulations.
General guidelines on the type of Personal Protective Equipment

to be used.
All workers exposed to head injury hazards must wear protective

headware to shield them from falling objects, blows, and electric shock
and burns. These devices include helmets (classified as A, B, or C); bump
caps; and hair protection. Before each use, helmets should be inspected
for any defects or signs of wear that can reduce their protective
effectiveness. Every 30 days or sooner, headware should be thoroughly
cleaned and disinfected.

Protection of eyes and face from injury is vital in any occupational

health and safety program. Protective devices include safety
glasses, goggles and face shields. Face shields alone generally do
not provide adequate protection against eye injuries and must be
combined with basic eye protective glasses or goggles.
Safety glasses and goggles should be large enough to shield the entire
eye socket area and should contain lens materials matched to the hazard
worker’s face, particularly for laser and welding operations. Hoods can
provide protection against chemical splashes. Both eye protection
devices and face shields must be kept scrupulously clean to avoid
contaminating the surface of the eyes or face.
Management must evaluate the workplace for hearing hazards

and determine the need for hearing protection devices. Daily work in
steady noise of more than 85 decibels for eight-hour shifts is considered
hazardous noise exposure. Hearing protection devices are given a noise
reduction rating that indicates their protective effectiveness, although real
world values may be considerably less.
Hearing protector’s fall into four categories: enclosure (helmets), aural

(ear insert formable, custom molded, molded). Each hearing protector
should be fitted to each worker, and employees must be taught proper
insertion techniques and maintenance procedures.
Fall protection is defined as a means of preventing workers from

experiencing accidental falls from elevations. Fall protection systems are
either passive (nets) or active (lifelines, harnesses etc.). In selecting the
right fall protection system, management should conduct a thorough job
survey analysis and establish a fall protection program.
Passive fall protection systems include personal and debris nets placed
beneath work areas to catch workers or falling debris. These nets can be
combined to serve as both personnel and debris nets for the same job.
Active fall protection systems include secure anchorage points and the
use of lanyards, safety belts, fall arresters and shock absorbers,
harshness retracting lifeline devices, horizontal and vertical lifelines, and
hardware connectors.

Companies must also develop rescue procedures for retrieving a fallen

worker from above ground, below-ground or confined spaces operations.
Fall protection equipment must be inspected, cleaned, and repaired or
replaced on a routine basis.
To protect workers from airborne health hazards, management must

provide respiratory protection equipment against gaseous, particulate and
combination contaminants and oxygen deficient environments. Proper
selection of equipment depends on the toxic substance encountered,
conditions of exposure, individual worker capabilities, and equipment fit.
Respiratory protection is evaluated according to a “protection factor” that
describes the overall effectiveness of the equipment.
Respirators are classified as air supplying or air purifying devices. Air

supplying respirators provide a breathing gas to the worker and include
(1) self contained breathing apparatus (SCBA); (2) supplied air devices;
and (3) combined supplied air SCBA respirators.
Air purifying respirators are classified as either gas/vapor devices (also

known as chemical cartridge respirators) or particulate devices. These
respirators are available in three configurations; quarter-face, half-face,
and full-face models. Each type provides increased protection against
higher concentrations of toxic materials.
Air purifying respirators must be properly fitted and tested using

qualitative, quantitative, negative pressure, and positive pressure tests.
All respirators must be routinely inspected, cleaned, and properly stored
to ensure their protective effectiveness. The company must establish a
complete training and medical surveillance program to make sure that
employees know how to use and maintain their equipment and that only
physically qualified personnel use respirators.
Safety footwear includes steel, reinforced plastic, and hard rubber

models, depending on the shoe design protective level required. Some
jobs require conductive, nonconductive, foundry, or chemical splashes.
Footwear must be kept clean and in good repair.
Special protective clothing is used to shield workers form such workplace

hazards as heat, hot metal, chemical splashes, weather extremes, and
electrical shock or burns. Such clothing includes leather garments, wool

and asbestos substitutes, aluminized clothing, flame resistant or flame-

retardant materials, aprons kneepads, gloves and gauntlets, hand
leathers and arm protectors, imperious materials, heat-stress and cold
weather clothing, and conductive or nonconductive clothing.
Specification for safety equipment is given in annexure – 1. In each

technical chapter of part II, whoever required specific personal protective
equipment requirements is dealt with.

Annexure – 1
SPECIFICATION FOR SAFETY EQUIPMENT
A SAFETY HELMET
Fibre glass HDP etc should weigh 400 to 450 gms and be
moisture shock and fire resistant. It should withstand 20 deg
and plus 50 deg. C. If a plumb bob of 500 gms weight with
conical steel point is dropped from a height of 3M there should
be no piercing or denting.
B SAFETY BELT
General purpose harness safety belt consists of one body belt

and two shoulder straps made from strong closely woven
approximately 50 mm wide 6 ply cotton webbing with 3 mm
long 12 mm dia tested quality polypropylene rope. All iron
fittings be galvanised and jointless cut from solid. A special D-
ring to be provided at the back of safety belt and life line is
directly spliced (minimum 9”) from back of D-ring.
C GOGGLES
(a) For chippers / grinders / hammer men clear glass 50 mm dia

with shatterproof toughened glass preferable panoramic view.
Face shield with headband may also be used.
(b) For welders / gas cutters heat proof unbreakable zero power
smoke colour glass of suitable shade according to the type of
hob with protective clear glass. The fibre frame should have
provision for side ventilation padded cup edge, leather
covered nosepiece, fitted with elastic headbands and
conformable to use.
(c) Over head grinding panorama goggles moulded PVC frame,

unbreakable flame proof with wide flexible and replaceable
plastic highly transparent full view ‘O’ optically correct visor

deep frame to fit over power spectacle indirect ventilation

fitted with elastic headband.
D GLOVES
(a) All leather made of chrome / calf leather 450 mm long with
five fingers double stitching for joints. The fit of gloves
should be such that the fingers have ample room and the
bridge connecting the thumb to the gloves should be
sufficiently deep so that the thumb will not cause strain on
the palm of the gloves. Stitching should be done with good
quality thread.
(b) For Electricians gloves made of rubber 380 mm / 450 mm

long tested to 15000 volts.
(c) For material handling leather cum canvas 304 mm long

double leather for palm single leather for five finger type,
double stitching with stitches spaced 1 mm from each other
with good quality thread. The cloth should be of thick cotton
canvas. The gloves should be comfortable to use so that
fingers have ample room and the bridge connecting the
thumb to the gloves should be sufficiently deep so that the
thumb will nto cause strain on the palm of the gloves.
Stitching done should not be too near the edge.
E DUST MASK
Cloth dust mask flannel type made from netting cloth outside and
fine canvas cloth inside sandwiched with 3 mm foam padding,
enclosing the mouth and the nose, with elastic head strap ensuring
safe breathing in dusty atmosphere.
F SAFETY NET
6 mm dia with twin rope inside for 50 mm x 50 mm meshing with

provision for intermediate rope of 12 mm dia every 1M and 20 mm
dia rope on all four sides, with provision for tying the net at every
one meter. All ropes should be made of tested quality
polypropylene rope. There should not be any joint in the mesh.

The safety net should withstand a load of 500 kg on 2.5 m span.

The safety net should pass through a drop test which specifies that
the deflection should not be more than 2 M or half the length of
shortest side when a sand bag of 140 kg mass is dropped
successively three times on to the centre of the net from a height of
50 feet.
G WELDING FACE SHIELD (HELMET TYPE)
Shield made of vulcanised fibre swivel type with adjustable sponge

padded head gear. Centre metal frame aperture to accommodate
glass of 107 x 82 x 3 mm size dark green colour of shade 11 DIN
sandwiched with a pair of clear protective glass of same size.
H EAR MASK
When noise level exceeds 85 to 90 decibels, ear muffs / earplugs

are to be used.

11. Occupational Health Center and First Aid at Construction Site
Serious or minor injuries are often occur at construction site. Therefore

first aid becomes essential to control the condition of injured to avoid
further deterioration. In order to give first aid immediately at accident
spot, some trained first-aid personnel should be available at the
Occupational Health Center which also monitors the health of the
personnel working at the site.
This procedure gives information about the following:
1. Duration of training.
2. Frequency to training.
3. Responsibility and arrangement of first aid training.
4. Maintenance of records.
5. Placement of first aid boxes.
6. Contents of first-aid box.
7. Minimum No. of trained first aiders.
• Duration of training: The duration of training shall be of one full day

to first aider and / or nominated persons at the site.
• Frequency of training: The frequency of training shall be six months

from the date of commencement of project or six months from the
date of issue of this procedure.
• Responsibility and arrangement of first-aid training program:

The responsibility to train the persons in first aid leis with RCM/RCE.
RCM/RCE shall arrange training program by engaging services of
agencies such as St. John Ambulance or other local agencies like
Hospitals, Govt. bodies etc.
• Maintenance of records: The record of each first aid treatment case

shall be recorded in a register, titled as "First Aid Register" (Annexure
3). This record should be maintained and be made available for the
audit team. In addition to first aid treatment cases, record of training
given to personnel should also be kept in a separate register, titled as
"Training Register". (Annexure 4)
Occupational Health Center and First Aid 1

• Placement of first aid boxes: Over every 50 workers a first-aid box

shall be provided at work site or at distance of 500 meters. One more
box for every additional 100 persons shall also be provided.
• Contents of First-Aid box: As attached in annexure I,& II.
• Minimum No. of trained first aiders: At any time of work at least 5

trained first-aiders shall be available at site.
RCM/RCE shall ensure the enforcement of this procedure:
1. Information about first aid shall be displayed at all prominent

locations at site.
2. RCM/RCE shall check and sign all registers pertains to first aid once
in every fifteen days.
3. All records maintained shall be checked by Safety Engineers from

SCD whenever they come for inspection/audit at site. If any
deviation found, that will be highlighted in inspection/audit report.

Annexure - I
Contents of First Aid Box
The first aid shall be distinctively marked with a red cross on a while
background and contain following:
1. Band aids (200 Nos.).For local application

2. Ointment Thrombhob (10 Nos.) For local application 2/3 times a day
3. Ointment Sofraycin (10 Nos.) Local application
4. Ointment Multigesic (10 Nos.) Local application
5. First aid sprays (2 Nos.) For burn / cuts / bruise etc.
6. Savlon lotion (5 Bottles) For cleaning of wounds
7. Tincture Benzoine (5 Bottles) For local application
8. Bandages all types 1/2/3" (20 Nos. each) For bandage
9. Cotton wool (10 Rolls.) For cleaning / use for dressing
10. Large size burn dressings (10 Nos.).
11. One pair of scissors.
12. One pair of adhesive plaster (2.5 cms X 1 Mtr.).
13. Jonhnson & Jonhnson Eye pads - 15 to 20 Nos.
14. Dettole Ointment Silversuphidezine For burns (One Nos.)
15. Eye Wash Bottle (One Nos.).
16. One copy of first aid leaflet.
Medicines
17. Caps. Amoxyciline 250 mg. (300 Nos.) 1Cap.Three times a day.
18. Tabs. Althrocine 250 mg. (100 Nos.) 1 Tab four times. a day
19. Tabs. Ibugesic plus. (500 Nos.) 1 Tab 3 times a day.
20. Tabs. Polycrol forte (PFT) (500 Nos.) 1/2 Tab at a time to be
chewed 2/3 times a day.
21. Tabs Metrogyl Compound (500 Nos.)/ 1 Tab. 3 times a day X 5
days.
22. Tabs Neobarb/Entro-quinol 1 Tab 3/4 times a day.
23. Tabs Domid (200 Nos.) 1 Tab 2 times a day.
24. Tabs Polaramine (200 Nos.) 1 Tab 2 times a day.
25. Tabs Avomin (100 Nos.) 1 Tab 2/3 times a day.
26. Tabs Vikoryl (300 Nos.) 1 Tab 3/4 times a day.
27. Tabs Crocin (500 mg) (500 Nos.)/ 1 Tab 3/4 times a day.

28. Tabs Placidox (2 mg ) 1 Tab SOS

29. Tabs Colinol P/ Spasmoproxyvon 1 Tab 3 times a day (200
Nos.)
30. Tabs Rantidine (200 Nos.) 1 Tab 2 times a day
31. Gentycin Eye / Ear drops (10 Bottles) 2/3 drops, 2/3 times a
day
32. Tabs Theo-asthaline (100 Nos.) 1Tab 2/3 times a day
33. Electral Powder - Small Pack (100 Nos.) For gassing
Note: All medicines to be taken after meals. Please ensure 'Medicine

allergy' to any of the above medicines, before consumption.

Annexure - II
INSTRUCTIONS
FOR FEVER / COLD CAPS. AMOXICILINE +

TABS. NEOFARBRIN OR
TABS. CROCIN.
FOR EAR PAIN CAPS. AMOXICILINE +
TABS. IBUGESIC
FOR HEADACH/ SLIGHT FEVER TABS. CROCIN
FOR SORETHROAT TABS.ALTHROCIN+CROCIN
FOR BRONCHITIS CAPS. AMOXYCILINE + ANY

COUGH SYRUP
FOR DYSENTRY TABS METROGYL COMPOUD
FOR SYMACH PAIN TABS. COLINOL P
FOR ACIDITY / GASTRICS TABS. PTF / TABS. RANTIDINE
FOR BONY PAIN/ BACKACHE/ TABS. IBUGESIC

CONTUSION INJURY/ RHEMATIC
PAIN
FOR SKIN ALLERGY/ REACTIION POLARAMINE

OR MILD COLD
FOR VOMITING/ GIDDINESS TABS. DOMID / TABS.AVOMIN
FOR SLEEP DISTRUBANCE TABS PALCIDOX 2
FOR ASTHAMATIC PROBLEMS TABS THEO-ASTHALINE
FOR LOCAL APPLICATION FOR MULTIGESIC CREAM

PAIN OR RHEUMATIC PAIN

FOR LOCAL APPLICATION NOT OINTMENT THROMBOPHOB

TO BE RUBBED - APPLY
SUPERFICIALLY - FOR
CONTUSIION INJUTY/ BLUNT
INJURY
FOR SMALL CUTS ETC. BAND AIDS/TINC. BENZOINE

FOR CUTS / BRUISES, BURNS SOFRAMYCIN CREAM

Annexure - III
The format for first-aid treatment register shall be as follows:
Sr. Name of patient Date Sex & Type of Part of Type of

No. Age Injury body Treatment
injured given

12. Electrical Safety
General :
Electrical Injuries:
Current flow and time are the factors that cause injuries in electrical
shock. The severity of electrical shock is determined 1) by the amount of
current that flows though the victim (Table 1), 2) by the length of time
that the body receives the current and 3) the part of body involved.
But current flow depends on voltage and resistance, these factors are
also important and if it is alternating current frequency. Heat is a
secondary effect on the body. Such current flow can easily be received on
contact with low voltage sources of the secondary lighting or power
circuit.
A person’s main resistance to current flow is the skin’s surface. Dry skin
has a fairly high resistance. A sharp decease in resistance takes place
when the skin is moist (Table 2). Once the skin’s resistance is broken
down, the current flows readily through the blood and the body’s tissues.
The resistance decreases rapidly with increase in voltage. Low voltage is
dangerous as it prevents the victim from breaking the contact with the
circuit.
Internal Injuries:
Death or injuries from electrical shock may result from the following
effects of current on the body:
1. Contraction of the chest muscles, which may interfere with
breathing to such an extent that death will result from asphyxiation
when the contact is prolonged.
2. Temporary paralysis of the nerve center, which may result in failure
to breath, a condition that often continues long after the victim is
freed from the circuit.
3. Interface with the normal rhythm of the heart, causing ventricular
fibrillation. In this condition, the fibers of the heart muscle, instead
of contracting in a coordinated manner contract separately and at
different times. Blood circulation ceases and unless proper
resuscitation efforts are made, death occurs. The heart cannot
__________________________________________________________
Electrical safety 1
spontaneously recover from this condition. It has been estimated

that 50 ma is sufficient to cause ventricular fibrillation.
4. On contact with heavy current, the muscular contractions of the
heart stop. The heart may resume its normal rhythm when the
victim is freed from the circuit.
5. Hemorrhages and destruction of tissues, nerves and muscles from
heat due to heavy current along the electrical circuit’s path through
the body.
6. Severe burns may result from contact with low-voltage systems in
cars, trucks and lift trucks when metal, wenches or jewelry make
contact with current carrying conductors. Injuries from electrical
shock are less severe when the current does not pass through or
near centers and vital organs. When current flows from the hands
to the feet involving both the heart and the lungs the results are
very serious.
Skin and Eye Injuries :

Another type of injury is burns from electrical flashes. Such burns are
usually deep and slow to heal and may involve large areas of the body.
Persons at a reasonable distance from the arc may receive eye burns.
Where high voltages are involved, flashes of explosive violence may
result. This intense arcing is caused by
1) short circuits between bus bar or cables carrying heavy current
2) failure of knife switches
3) operating knife switches while they are carrying a heavy load
4) pulling fuses in energised circuits
Injuries from Falls

Other injuries from electrical shock include falls from one level to
another. When worker receives a shock from defective or malfunctioning
equipment causes muscles to contract so worker loses his balance and
fall.
Cardiopulmonary Resuscitation ( CPR)

Because electrical shock can stop the heart and lungs the worker involved
in hazardous energy levels know cardiopulmonary resuscitation (CPR)
and rescue procedure. Immediately apply CPR to a victim of electrical
shock and continue until they revive.
__________________________________________________________
Electrical safety 2
The Risk Due to Use of Electricity at The Site:
• Construction sites present one of the most challenging work

environment for the safe use of electricity. Much of the work is carried
out outdoors in all weather conditions thereby increasing the risk and
the severity of the electrical shock. As the work progresses, the site
keeps on shifting inducing the contractors to adopt / improvise supply
systems. Excavations, demolitions and routine work may all result in
damage to both the temporary site distribution system and / or the
permanent installations.
• The cables and equipment are likely to be damaged by the movement

of heavy plant and materials. Congestion at the sites and also the
difficulty in identifying the energised and dead installations may also
increase the risk.
• Different contractors with varying methods and different tools further

aggravate the risk due to the usage of the same facility.
Planning the work:
• Planning helps in removing most of the inherent risks at the initial

stages itself. The Building code and the statue the necessary
requirements to provide a risk free work environment. As a first step,
a suitable person should be appointed to plan the work. He should
make the line diagram.
• As a next step, the possibility of eliminating the risks should be

explored such as the provision of pneumatic tools instead of electrical
ones in wet conditions. In such cases low voltage system (max. 50 V)
or reduced voltage system (110 V system which provides only 55 V
between phase and earth in single phase system) or system provided
with residual current device can also be considered.
• Try to tackle the risk if it cannot be completely eliminated and give

priorities to the control of risks that could directly result in injuring the
workers.
__________________________________________________________
Electrical safety 3
• At the design and planning stage, and as the project develops, issues
which need to be considered or reviewed will include the following:
! Giving intimation to the state authorities for providing power

supply for commencing the work.
! Location of overhead lines and buried cables.
! Environmental conditions such as weather.
! The supply voltage required.
! The need for providing alternate power for augmenting the
supply requirements.
! Earthing requirement / system to be used.
! The installation and commissioning of the temporary site
distribution system, in particular the siting and protection of
metering equipment and switchgear, distribution boards and
supply cables.
! The way in which the system will be modified /extended as the
work progresses.
! Operation of temporary system and the use of plant and
equipment connected to the distribution system.
! Provision of lockable switches and means of isolation.
! Use of existing permanent systems as a supply for plant and
equipment.
! If refurbishment works are to be carried out, identification of
parts of the system which are alive.
! Commissioning and handover arrangement for completed
buildings or installations.
Most of these issues are covered in the following chapters.
Selection of equipment for the temporary site distribution system:
• While selecting equipment particular attention should be paid to any

restriction on use specified by the manufacturer.
• Site distribution units should be designed and manufactured to a
suitable standard and should have features like repeated usability,
easy transportability, sturdiness and lockable switches and means of
isolation.
__________________________________________________________
Electrical safety 4
Staff Appointments:
• Before starting work the principal or main contractor/s should appoint

key personnel responsible for electrical installation. Their competency
is based on their training and experience, knowledge of the risks
involved in their job and the ability to complete them safely.
Electrical Equipment Locations

1. The entrances to enclosures containing exposed high voltage
energised parts, such as transformer switch yards, generator
line and neutral cabinets or rear entry motor control centers,
shell be kept locked. Access doors or gates to rooms, vaults or
fenced enclosures containing electrical equipment shell be
readily opened from the inside without the use of a key.
2. Permanent and conspicuous warning signs shell be posted on all
doors or gates that provide access to enclosures containing
exposed energised parts and conductors forbidding unqualified
persons to enter. Such signs shall be legible at 12 feet, of
sufficient durability to withstand the environment involved, and
shall read substantially as follows:
“WARNING – HIGH VOLTAGE – KEEP OUT “
Some typical site situations along with the precautions to be

taken are given below:
Generators:
A supply from electrical board is not always available. In these instances
the electricity supply for the site can be provided by an ac generating set.
Care is needed to ensure that the generator is installed safely and expert
advice may be needed particularly on earthing.
For small-scale work, or in locations remote from the site supply, portable
generator (with outputs of up to 10kVA) are often used. For short time
work (e.g. less than one day), these generators need not be earthed
provided that they are only used with ClassII (double insulated or all –
insulated) tools or equipment.
__________________________________________________________
Electrical safety 5
The smaller, single phase generators used for 110V supplies, (i.e. those
with ratings up to about 5kVA) need not be earthed, if all the equipment
in use is double insulated, or if it is supplies only one item of “earthed”
equipment. However, the equipment should be bonded with the frame of
the generator. (Bonding involves connecting items of metalwork together
in a way that is electrically continuous.)
In all other circumstances, a suitable earth should be provided.
When larger generators are used (output in excess of 10kVA), the

generating set may be either single or 3 phase. Particular care is needed
to ensure that the system is installed safely and this may require
specialist advice. Matter to consider include the following:
" Generator needed to be earthed, by bonding the neutral to the
frame and connecting the frame to earth;
" The impedance of the bonding needs to be low enough to ensure
correct operation of protective devices (fuses, circuit breakers
etc.)
" Sensitive earth fault protection may be necessary if earthing
conditions are difficult.
Further guidance on earthing and bonding of generator system are given

under appropriate headings.
Generator should be connected and operated so that they are separate

from the public supply system unless agreement has already been
obtained in writing from the electricity authorities.
Earthing:
Electrical safety often depends upon the existence of effective earthing.
The responsibility for ensuring that the electrical earthing is effective
rests with the person in charge of the site, not with the electricity
supplier.
" Many electricity suppliers systems use protective multiple earthing

(PME). (In these systems neutral and earth are combined.) Where a
PME system is used all metalwork, including structural metalwork,
must be bonded together (connected together in a way that is
electrically continuous). This is generally difficult to achieve on a
__________________________________________________________
Electrical safety 6
construction site for a variety of reasons, particularly where

steelwork is being added in the course of the work, where steelwork
has been treated against corrosion or where individual metal framed
portable buildings or cabins are used. Therefore most electricity
suppliers will not connect the site electrical system unless there is
an adequate alternate earth. The use of an earth from a PME system
is not allowed for the electrical supply to site caravans.
" There are several alternative methods of providing a secure and

effective earth. On a construction site a system that uses earth
electrodes is most commonly used and will ensure that fuses etc will
operate if there is a fault. Where necessary, specialist advice should
be sought to ensure that there is adequate electrical protection.
Guidance can be taken from relevant BIS.
" If the work involves extending an existing site or structure, the

existing electrical installation may be supplied from a PME system.
In these circumstances it is strongly recommended that temporary
site distribution system which, for their effective earthing, depend
on the provision of their own earthing electrodes, are kept separate
from the PME system.
" Fixed cable armouring and metal conduit can be used as a protective
(earthing) conductor. Flexible metallic conduit should not be used as
the only earthing conductor; it needs to be bonded (metalwork
connected together in a way that is electrically continuous) and a
separate protective (earth) conductor will be necessary.
" The effective operation of any electrical protection depends on a low
resistance earth path in the event of a fault. Joints in the earth path
are particularly vulnerable to damage so there should be good
electrical connection between the various componets, e.g. between
conduit, cable glands, and the equipment. Additional electrical
connections between the various metal parts may be necessary to
provide this low resistance path, ensuring reliable operation of fuses
etc.
" Guidance on earth impedance values is contained in BSI
Requirements for electrical installations. Specialist advice on
appropriate values may be necessary. Earthing should always be
tested after an item of equipment has been installed, paying
particular attention to the continuity of protective (earthing)
__________________________________________________________
Electrical safety 7
conductors, as well as to the polarity and to insulation resistance.

See BIS for the above.
Earthing equipment connected to the supply:
" Equipment that is either double insulated, (constructed with two

layers of insulation to provide electrical protection in case of damage
to the outer insulation) or all insulated, (constructed with reinforced
insulation) does not need, and will not be fitted with a means of
connected to earth. Double insulated equipment is marked with this
symbol:
and will therefore be supplied with a two core cable only.

Equipment, which is not double, insulated or all insulated must be
earthed. A three-core cable will be needed.
" If extension leads are used, it is strongly recommended that these are
always of three core construction having a separate protective
(earth) conductor. This will ensure that the supply to tools, which
are not double insulated, always includes an earth.
The temporary site distribution system:
" This is the cabling system and equipment installed to distribute and
supply electricity to points of use at the various locations on the site
during the construction phase. The temporary site distribution
system is always removed when site work is completed, as it is then
no longer required. Removal may begin on completion and
commissioning of all or part of the permanent, fixed installation.
" Although the site distribution system may be only temporary, the harsh
conditions on site require that it is to a high standard. Equipment
must be adequately protected against damage and contamination
due to dust etc.
__________________________________________________________
Electrical safety 8
" Switchgear and metering equipment should be provided with secure

accommodation, and protected from adverse environment
conditions. It should preferably be located at a place where it is less
likely to be damaged. Make sure that switchgear, and in particular
the means of turning off the supply, is accessible at all times in case
of emergency.
Uses and other Protective devices:
" The use of correctly rated fuses and / or circuit breakers is essential for
all the supplies on site.
" Makeshift arrangements, such as unprotected wiring, taped and twisted
cable joints, are often dangerous and should not be permitted. All
wiring on site should be installed to appropriate standards.
" Distribution cables should be located where they are not likely to be
damaged by site activities. They should be kept clear of
passageways, ladders and other services. If they need to cross a
site roadway or walkway they can be put into ducts with a marker at
each end of the duct. If the roadway is used by vehicles, the duct
should be at least 0.5m below the surface. A record of the location
any underground cables, using maps or plans showing the line and
depth of such cables will be invaluable in avoiding damage as work
progresses. Alternatively, cables properly protected can be carried
at a suitable height above the roadway or footway. A goalpost type
system may be required.
" All fixed distribution cables which carry 400V or 230V on a construction
site are recommended to be of a type which has metal sheath and /
or armour which is continuous and earthed. The metal sheath and /
or armour should be protected against corrosion.
" Site offices and fixed floodlighting will generally require 230V supplies.
Installation within site offices and the other buildings should be to a
suitable standard. The equipment should be suitable to the
surrounding enviroment.
" It is strongly recommended that, on larger sites, any existing or new
permanent fixed supply contractors’ equipment during the
construction work. This will minimise unauthorised interference with
the permanent fixed installation.
Moveable Plant:
__________________________________________________________
Electrical safety 9
" Plant such as lifts and hoists, which may be relocated occasionally
during the work, is recommended to be supplied by armour cable.
If, in the course of the construction operations, the plant is to be
relocated, a safe method of work must be adopted. This will include
turning off the supply and disconnecting the cable before the plant
and cables are moved. Plant which is moved frequently (e.g. a
cement mixer) should be connected to the supply by a flexible cable
with protective braid and abrasion-resistant sheath. Cables will need
to be suitably located and adequately protected so that they will not
be damaged.
" If equipment has a high current requirement (current ratings greater
than 16 amps), arcing can occur if the plug and socket are
separated under load, causing burn or other injuries. Ways of
isolating the supply should be provided to ensure that the supply is
switched off before the plug and socket are separated.
Portable Equipment:
" Portable equipment and its leads face harsh conditions and rough use.
Equipment is likely to be damaged and may become dangerous.
Modern double insulate tools are well protected, but their leads and
plugs are still vulnerable to damage and should be regularly
checked. It is essential that the type of equipment selected is
suitable for use on a construction site, and that any restrictions on
use given by the manufacturer are followed.
" The site supply voltage will often influence the choice if equipment.
Where the supply is 230V or above, contractors can themselves
eliminate or reduce the risks by selecting cordless tools or tools,
which operate, from a reduced low voltage supply, (e.g. 110V
systems which are center tapped to earth). For lighting, lower
voltages can be used and are even safer.
" There have been fatal accidents where 110V equipment fitted with plugs
designed for a 230V system or damaged.110V plugs have been
plugged into 230V supplies. To avoid danger, plugs and sockets
used on the reduced low voltage system should not be
interchangeable with 230V (mains) plugs and sockets. These
industrial plugs and sockets are more robust than domestic type
equipment, which is not designed for use on construction sites.
__________________________________________________________
Electrical safety 10
" Cables with solid conductors (non-stranded) are designed for use in
fixed installations. The conductors inside are brittle and liable to
break if bent, so they should not be used as either extension leads
or replacement cables for portable equipment.
Use of main voltage equipment:
" When main voltage equipment is used on construction sites, the risk of
injury or death arising from the use of damaged or faulty
equipment, leads or plugs is unacceptably high unless special
precautions are taken. The precautions must reduce the risk to an
acceptable level taking into account the constraints regarding RCDs
mentioned in following paragraphs. Reasonably practicable
precautions include:
(a) Protecting people who may receive an electric shock by fitting

non-adjustable residual current devices (RCDs) with a rated
tripping current of 30mA. RCDs should be installed either at
the distribution board, which feeds the mains supply sockets,
or at the fixed mains supply socket. In either of these positions
they will provide protection for both the cable and tool. RCDs
fitted close to the tool only protect the tool. RCDs should be:
" Installed in a dustproof and weatherproof enclosure (see
the manufacture’s instructions) or designed for use in
dusty and outdoor environments;
" Protected against mechanical damage and vibration;
" Checked daily by operating the test button;
" Inspected weekly together with the equipment it is
supplying during the formal visual inspection;
" Tested every threee months by an electrician using
appropriate electrical test equipment.
NOTE: The tests should not be carried out on RCDs at a time
when loss of power may adversely affect other work activities.
(b) Reducing the risk of flexible supply leads being damaged by:
" Positioning them where they are less likely to be

damaged, (e.g. run them at ceiling height inside a
building); and / or
__________________________________________________________
" Protecting them inside impact resistant conduit where

appropriate; or
" Using special abrasion resistant or armoured flexible
supply leads where appropriate.
(c) Selecting tools that are designed for trade and work use.
Double insulated equipment is strongly recommended where it
is necessary to use a main voltage supply, because the tools
themselves are less likely to give rise to danger. (Danger can
still arise, however, if the cables, plugs or equipment casing
are damaged). Any restrictions on use out in the
manufacturer’s instructions should be observed.
(d) Regular maintenance checks which should be made of all

electrical equipment. These should include:
" Checks by the user each time the tool is used;

" Formal visual checks by a trained person on a regular
basis.
" Combined inspection and testing by a trained person at
suitable intervals depending on the risk of damage and
the potential for injury.
__________________________________________________________
Residual Current Devices (RCDs)

" Due to the delicate nature of an RCD, it is not ideal for use in
the rough environment of a construction site. It may not be
possible to ensure that the housing for the RCD is maintained to
the quality required in these locations, and control over the
number of times the test button is operated may be difficult. The
manufacturers of RCDs do not generally recommend them to be
fitted on portable apparatus that may receive mechanical shock
or on equipment that might vibrate. In case if it is decided to
use RCD in the system then it’s limitation should be taken into
account.
" If an RCD fails to operate, or is faulty, this will not be indicated
and the worker may remain unaware of the danger. They only
protect against earth faults and will not operate when there is no
connection to earth, ie if current is passing from live to neutral.
So it is possible to suffer an electric shock and injury even
though the RCD is operating correctly.
" RCDs for protecting people have a rated tripping current of not
more than 30mA and operating time of 200 milliseconds(ms) or
150mA for 40 ms.
Maintaining portable electrical installation

On construction sites, the risks from damaged or faulty portable electrical
equipment are high and need to be managed and controlled by
appropriate maintenance system.
" Formal daily visual inspections on a regular basis because this
can detect about 95% of faults or damage.
" Checks by the user.
" Combined inspection and electrical testing where necessary.
" Check daily RCDs.
" Bare wires are not visible
" The cable covering is not damaged and is free from cuts and
abrasion.
" The plug is in good condition, the casing is not cracked, the pins
are not bent or the socket is not blocked with loose material.
" There are no taped or other non-standard joints in the cable.
" The outer sheath of the cable is gripped where it enters the plug
or equipment.
__________________________________________________________
" The outer cover of the equipment is not damaged or loose and
all screws are in place.
" There are no overheating or burns marks on the plug, cable or
the equipment.
" It is serviced regularly in line with the manufacturer’s
instruction.
__________________________________________________________
Annexure – I
General Precaution
" Implement lockout / tagout procedures prior to performing any electrical
work.
" Make dielectric tests on rubber gloves and blankets at regular intervals.
They should be air tested daily before use and kept powered.
" Notify all personnel concerned before starting any electrical equipment.
" Always assume a circuit is energised until you have checked it.
" Do not energise a tagged starter or switch without first properly
removing the ‘lock-out/tag-out’.
" Always remove the load from a circuit before de-energising it.
" Ventilate the working area well and keep fires and sparks away from
charging batteries since the acid fumes explode as hydrogen gas is
generated while charging a battery.
" Never use water on an electrical fire.
" Never look directly at open switches or breakers when energising or de-
energising to avoid retinal burns.
" Only trained authorised personnel should perform maintenance and
repair work on electrical equipment.
" When repair work on energized circuits must be made, the following
precautions must be taken:
(a) Work must be performed only by trained and experience

personnel.
(b) There should be ample light.
(c) The worker should stand on non-conducting material such as
layers of dry canvas, dry wood or rubber.
" Never pull any fuse that is carrying current. Never break a circuit under
load, severe arcing may occur.
" Use approved tools and “hot” circuit handling equipment when working
on energized equipment. Be thoroughly familiar with the circuit to
be worked on.
" Personnel should be stationed near the main switch or circuit breaker so
that the equipment can be de-energized immediately in an
emergency.
__________________________________________________________
" Metal ladders and scaffolds are electric conductors, they should never be
used around electric circuits or in place where they can come in
contact with electrical circuits.
" Extension cords should not be tied to electric outlets. These cords must
be free so they can be unplugged in an emergency.
" Use hand line when raising or lowering tools. Never lower electrical tools
by the cord.
" Cable trays are not designed to support loads, to be walked on, or used
to secure safety belt lanyards.
" Always de-energize circuits before attempting to reset them.
" Follow the following safe work practices:
Table1 - Safe work Practices
Voltage Remove Insulated Rubber Eye Rubber Safety Safe

Jewelry tools Gloves Protection Matting Signs Distance
(Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Table
2/3)
Line (a)
0-150 Y Y N N N Y
Table 2
Line (b)
151-300 Y Y N N N Y
Table 2
Line (b)
301-600 Y Y Y Y Y Y
Table 2
>600 (*) Y Y Y Y Y Y Table 3
(*) In no situation are SSOI employees authorized to work on or near

energized circuit parts or equipment when the voltage level exceeds 600
volts, nominal due to the extreme dangers associated with and the lack
of frequent experience working on high voltage systems. In these
situations, a licensed electrical contractor must be used.
__________________________________________________________
Annexure - II
Working Clearance (Safe Distance):
The dimension of the working space in the direction of live parts

operating at 600 volts or less and likely to require examination,
adjustment, servicing, or maintenance while energized shall not be less
than indicated in Table 2 and less than indicated in Table 3 for live parts
operating at greater than 600 volts. Distances shall be measured from
the live parts if such are exposed, or from the enclosure front opening if
such are enclosed.
Table 2 working Clearances (less than 600 volts)
Nominal Voltage to Minimum Clear Distance for Condition

Ground (I) (II) (III)
(ft) (ft) (ft)
0-150 3 3 3
151-600 3 3.5 4
Table 3 Working Clearance (greater than 600 volts)
Nominal Voltage Minimum clear Distance for Condition

to ground (I) (II) (III)
(ft) (ft) (ft)
601-2,500 3 4 5
2,501-9,000 4 5 6
9,001-25,000 5 6 9
25,000-75kV 6 8 10
Above 75kV 8 10 12
Where for both Tables 2 and 3 conditions (I), (II), and (III) are as
follows:
(I) Exposed live parts on one side and no live or grounded parts on the
other side of the working space, or exposed live parts on both sides
effectively guarded by suitable wood or other insulating materials.
Insulated wire or insulated busbars operating at not over 300 volts
shall be considered live parts.
(II) Exposed live parts on one side and grounded parts on the other side.
(For Table II; concrete, brick, or tile walls will be considered
grounded surface).
__________________________________________________________
(III) Exposed live parts on both sides of the workspace (not guarded as
provided in condition (I)) with the operator between.
NOTE : Distances shall be measured from the live

parts if such are exposed or dorm the enclosure
fronts or opening if such are enclosed.
HEADROOM: In both cases (600 volts or less and greater than

600 volts), the minimum headroom of working
spaces about service equipment, switchboards,
panelboards, or motor control centers shall be 6 ft
3 in.
__________________________________________________________
Annexure - III
Overhead Lines:
When work is performed in locations containing energized overhead lines

which are not guarded, isolated, or insulated, precautions shall be taken
to prevent employees form contacting such lines directly (through the
body) or indirectly (through conductive tools or equipment, i.e. ladders).
When work near overhead lines is required, minimum distance shall be
maintained to those lines in accordance with following table.
Nominal Voltage to Ground Minimum Distance

50KV or below 10 ft.
50KV or above 10ft. + **
** Add 4 in. for each 10 KV above 50 KV
__________________________________________________________
Annexure – IV
Personal Protective Equipment:
" Protective clothing and equipment:-

Employees shall be safeguarded from injury by utilizing appropriate
protective equipment while working in situation in which there are
potential electric hazards. All personal protective equipment shall be of
safe design and construction for the specific part of the body to be
protected and for the work to be performed. All protective equipment
shall be inspected prior to each use, shall be tested annually, and shall
be maintained and stored in a safe, reliable condition.
" Eye and Face Protection:-

Suitable eye or face protection shall be worn for voltages in excess of
300 volts, nominal and when performing work on exposed energized
parts of equipment where there is a danger of injury to the eyes or
face from electrical arcs or flashes.
" Electrical Safety Gloves:-

Suitable insulated gloves shall be worn for voltage in excess of 300
volts, nominal sees table 2 for glove classes and according voltage
rating. Whenever rubber gloves are used, they shall be protected by
outer leather or canvas gloves. In addition, rubber gloves shall be air
tested prior to each use, and leak tested every six (6) months.
Table 2
Class of Nominal Maximum Use Voltage, Phase a-c, rms.

Insulating Item
0 1,000
1 7,500
2 17,000
3 26,000
4 36,000
Note: The a-c voltage (rms) classification of the protective equipment

designates the maximum nominal design voltage.
__________________________________________________________
13. Non-Destructive Testing
Visual observation, even with magnification, cannot locate all small,

below-the-surface defects in cast and forged metals, or in weldments,
such as found in pressure vessels, boilers, and nuclear components.
Proper nondestructive testing, however, reveals all such defects without
damaging the parts being tested. Nondestructive testing methods locate
the following defects:
• defects that are inherent in the metal, such as nonmetallic
inclusions, shrinkage and porosity.
• defects that result from processing such as high residual stressed
cracks and checks caused by handling, shruing, or grinding of
casting and forging.
• in-service defects, such as corrosion, erosion, and sharp changes in
section.
The types of testing most commonly used for forged and cast metals
are the following:
1. Magnetic Particle Inspection
2. Penetrant Inspection
3. Ultrasonic Methods
4. Triboelectric Method
5. Electro-magnetic Tests
6. Radiography
These methods, as well as others that apply to nonmetallic substances,

are fully discussed in National Safety Council Industrial Data Sheet
12304-0662, Ultrasonic Non-destructive Testing for Metals.
Recommendations for installation, inspection and maintenance of the
electrical equipment used in many of these testing procedures are given
in Chapter 15, Electrical Equipment, in this volume.
13.1 Radiography
Radiography uses x-ray and gamma rays. X-rays are unidirectional and
their wavelengths can be varied, within certain limits, to suit the
Non Destructive Testing 1

condition. Gamma radiography differs from x-ray radiography in that

the gamma rays are multidirectional and their wavelengths being
characteristic of the source, cannot be regulated. Gamma rays for
radiography usually are obtained from isotopes of cobalt-60 or iridium-
192.
In some instances, gamma-ray exposures are inferior to x-ray

exposures in sensitivity and contrast. Gamma radiography, however,
has several advantages. Because of the nature of isotopes, a number
of tests can be made at tha same time, provided that specimens can be
suitably located. Moreover, isotopes are independent of electrical
power, their sources are portable, and the small size of the sources
makes it possible to obtain radiographs in tight quarters.
Devices used to transform differences in intensity of the penetrating

radiation into visible images are x-ray films, fluorescent screens,
proportional-scintillation geiger counters, and ionization gages. All
sources of ionizing radiation are potentially dangerous. X-ray and
Gamma rays sources may also produce hazardous secondary radius.
In addition, X ray units involve both low and high potential electrical
hazards.
The following are details of hazards and remedial measures to be taken

while handling and shruing radioisotopes.
Isotopes
Radioisotopes commonly used in industrial radiography are Cobalt-60

and Iridium-192, which are artificially produced by bombarding with an
excess of neutron, 192 & 60 represent mass number (atomic weight) of
the isotopes.

Radiation quantities and Units :
Curie :
Radiography of a source is measured in terms of numbers of
transformation it undergoes in one second. The unit for radiography is
Curie. Which is corresponding to 3.7*1010disintegration per second.
Curie shows the strength of the material.
Unit used for exposure is Roentgen (R)
The special unit of equivalent ionising dose presently used is Sievert
(Sv).
1 Sv = 100 R (Roentgen)
Dose Limit :
Since radiation causes undesirable effects on the body tissue. It is
important to observe the maximum permissible levels of radiation,
which have been recommended. International commission on
Radiological Protection (ICRP) sets guidelines in the form of annual dose
limits to individual. Setting dose limits below the threshold dose limit
(maximum permissible limit) can prevent any effects due to radiation
Definition of Permissible dose:

“ A dose of ionising radiation that will not cause any appreciably bodily
injury to a person at any time during his lifetime.”

Permissible limit:
Organ or In a In a year In a In a week

Tissue lifetime quarter
Whole body Red 300 50 mSv 30mSv 1mSv
bone marrow mSv
& On hands.
Skin or bone _ 300 mSv 150 mSv _
Tissue & thyroid
Extremities _ 750 mSv 150 mSv _
Any other _ 150 mSv 80 mSv _

organs, Lens of
eyes
Monitoring of radiation dose :
Personal monitoring: The most commonly used personal monitoring

devices are photographic film badges and pocket dosimeters. The
devices are designed to give cumulative reading of exposure measures.
X and Gamma radiation exposure in Roentgen. The operator of
radiography camera uses the personal monitoring devices.
Area monitoring: Most commonly used device is Survey meter. The

survey meter is used to check the radiation zone this meter is designed
to give instantaneous reading in Roentgen or milli-Roentgen per hour at
any distance from the source.
Control of radiation hazard:
The three basic factors by which radiation hazard can be

controlled are
(a) Time, (b) Distance, (c) Shielding

Time:
The radiation dose received by person depends on the total time spent
by the person near the source. Lesser the time spent near the source,
lesser would be the radiation dose.
If an operator takes one minute while working with a source and

exposed to 10mR, another operator who takes 2 minutes to do the
same job would be exposed to 2*10 = 20mR
In order to minimize the time of exposure -

1. Plan all operation in advance.
2. Carry out dry run with out radiation, so that with radiation, the
exposure time can be reduced.
3. Share work load with two person if the time exposure is large
Distance:
Larger the distance, lesser will be the radiation level. The most
economical and effective method of reducing the radiation hazard is to
increase the radiation distance between the radiation source & person.
The radiation intensity or radiation level from a given source decreases

as we move away from the source it is governed by the inverse square
law.
Shielding:
Shielding is the absorbing material is provided in order to reduce the

radiation intensity to the required value. The shielding properties of any
material depend on its atomic number and energy of the incident
radiation. Most commonly used shielding material is lead.

Storage of radioactive material.
1. The contractor has to obtain approval from Radiological physics

and Advisory Division. (RP & AD) BARC for storing radioactive
material.
2. Prepare pit room at the site for which approval is to be obtained

from BARC. The pit room consisting of the two compartments.
3. Keep pit rooms in locked condition. This should always preferably

in a least occupied area.
4. Do not allow entry of unauthorised persons near the work area.
5. Provide barbate fencing all around the pit room.
6. A logbook is to be maintained in order to record the day to day

use of radiography source stored in storage room.
7. Check surrounding area for radiation after the radioactive

materials are stored ensure that radiation level around the room
is less than 0.25mR/hr.
8. Ensure that all walls, floors, ceiling & doors is having sufficient
shielding so as to minimise radiation level below the
recommended limit.
9. There should not be any window of the exposure room.
Transportation for Radiography Source
1. Make sure that the source has returned to the camera.
2. Lock the camera to ensure that the source assembly would not be
released.

3. Source to be properly marked labeled.
Safety in Field Radiography
1. There should be a site-incharge looking after the radiation safety.

Because the radiography site-incharge is specially trained for
emergency handling procedure.
2. The operation to be carried out only when minimum nos. of

persons is present around the radiography site preferably during
nighttime.
3. The site in-charge and the cameraman are to be certified by

BARC.
4. The operator of radiography equipment should use personal

radiation monitoring badges or dosimeters.
5. Area around the source to be cordoned off using

ropes/barricading tapes and radiation warning symbol and
nighttime with red lamps. The exact area to be cordoned of
depends upon the nature & activity of the source, type of
exposure workload and the nature of occupancy around. Suitable
radiation monitor (survey meter) should be used to measure the
radiation level to ensure that the cordoning area is adequate.
Radiation level beyond the cordoned off area should be less than
0.25mR/hr. Ensure that survey meter for proper working
6. Setting up procedures required for radiography shall be completed

before start of radiography exposure.
7. The operator of radiography equipment shall maintain a log book

to record the details of day to day use of equipment.

8. The source container to be placed in such way that the radiation

beam can be made ‘ON’ towards unoccupied area.
9. Maintenance and servicing of radiographic material shall no be

attempted without consulting radiographic safety officer.
10. The operator should be aware of the dose record and send the
records for periodic medical examination.
11. Mock drill to be carried out before starting any radiography

operation. Time taken for coming down should not exceed the
safe exposure time.

14. Abrasive Blasting and Spray Painting
Abrasive blasting
Sand blasting operations can be overlooked when preparing safety plans

because they are generally a small part of a larger project such as
cleaning and refinishing or painting. As a result, many workers are
exposed to the hazards of sand blasting without adequate protection.
Even if all sandblasting equipment is properly designed and regularly
inspected, users must always be alert to the hazards of these operations
and take precautions against harmful exposures.
Airborne dust
This is one of the most serious hazards associated with blasting

operations. When evaluating this hazard, it's important to consider the
concentration of dust and the size of particles. Larger particles,
considered "nuisance" dust, are normally filtered out in the nose and
throat. Smaller particles (10 microns or smaller) can bypass the lung's
filtering system and penetrate deep into the respiratory system where
they may cause serious damage. Safeguards are needed when smaller
particles are present in the work environment.
Metal dust:
In addition to the abrasive being used, contributes to the generation of

airborne dust. Metals such as lead, cadmium, and manganese, can be
extremely toxic when inhaled. Many existing paints are lead based.
Regulations require special handling, trained personnel, and medical
monitoring when lead is present.
Silica sand:
This product is a potentially serious health hazard and should not be used
as an abrasive. If silica containing (quartz) materials are selected for
any reason, workers must wear a positive pressure or pressure demand
respirator with an assigned protection factor (APE) of either 1000 or
Abrasive Blasting & Spray Painting 1

2000. Silica must be contained and disposed of properly. Even if a wet

blasting method is selected, silica that is allowed to migrate by either
wind or water, will eventually become an airborne contaminant.
Air supply:
Air-supplied respirators must be used:
- When working inside of blast cleaning rooms,

- When using portable units in areas without enclosure, and
- Under any circumstances where the operator is not physically separated
from the abrasive material by an exhausted enclosure. If airline
respirators and compressors are used, it should be made sure that the
intake hose is placed in an area that provides clean air. An attendant
should be in the area at all times, monitoring breathing air and
assuring the Blaster’s safety.
Additional personal protective equipment:
Blasting operations create high noise levels, so hearing protection is a

must--for both the operator and nearby workers. Operators should also
use full body protection while doing the sand blasting operation.
Manual cabinet blast cleaners should never be exhausted into an area

where workers are allowed to move / work, as they would be breathing
the contaminated air.
These fully enclosed cabinets are designed to filter out dust and re-use
blasting medium.
Handling and storing abrasives:
Dust is always created at any point where abrasives are transferred,

whether by hand or shovel. Therefore, all points of transfer must be
properly exhausted and workers who handle abrasives manually should
wear appropriate breathing apparatus.

Spray Painting
Hazards
Painting and paint removal present hazards requiring effective controls.

Hazards include exposure to toxic materials and flammable or explosive
mists, particulates, and vapors.
Inhalation of mists and vapors from nearly all paints, solvents, thinners,
cleaning chemicals, strippers, and epoxies can be injurious depending
upon the agent's toxic characteristics and the amount and method of
exposure.
Further, many paints can physically injure the skin and eyes, or be
absorbed through the skin. Potential physical and health hazards can be
effectively controlled by appropriate work procedures, controls, facility
design, protective clothing, and equipment.
Safety
1. Pressure Equipment
Pressure equipment used in painting operations is hazardous because of

the compressed air component; therefore, the supervisor should ensure
that spray painting equipment is in serviceable condition. On all air-type
spraying equipment a pressure regulator valve shall be installed in the air
line between the compressor and painting equipment. A pressure relief
valve and a pressure gauge shall be installed between the pressure
regulator and pressurized paint containers and/or spray guns. Pressure
relief valves shall be set to open at pressures not more than 10 pounds
above the required working pressure.
2. Other Equipment
Painter's ladders, scaffolds, and other equipment shall be inspected prior

to use to be certain they are in safe condition.
3. Paint Mixing
Paint mixing shall be done in designated, adequately ventilated rooms

constructed of fire-resistant materials. All sources of ignition shall be

prohibited in mixing areas. All electrical fixtures or equipment in or within

20 feet of designated paint preparation areas shall meet the
requirements of the BIS Code.
4. Housekeeping
Good housekeeping is essential to safe operations in paint shops. Paint

rooms, booths, etc., shall be kept clean with equipment stored in a
proper and orderly manner. All solvent / paint soiled rags shall be placed
in approved self-closing metal containers plainly marked to indicate the
contents. At the end of each day, these containers shall be emptied or
removed to an approved location for pickup and disposal.
Health
1. Personnel Exposures
There is a wide application of organic solvents in painting. All organic

solvents have some effect on the central nervous system and the skin.
The principal modes of personnel exposure are inhalation of vapors and
absorption through skin contact and ingestion. Personnel engaged in
painting operations should review Material Safety Data Sheets (MSDS) in
order to acquaint themselves with the properties and hazards of the
solvents that are used
2. Protective Equipment
Personnel engaged in painting and paint removal shall wear BIS

approved protective clothing, respiratory devices if required, and
appropriate face, eye, and hand protection. Eye or face protection is
required during scraping or paint preparation (abrasive techniques).
Clothing shall be changed, as needed, to minimise body contamination.
3. Personal Hygiene
The hands and face shall be kept clean, clothes shall be changed when
contaminated.
No food or drink shall be brought into, or consumed, in paint shops.
Personnel shall wash their hands prior to smoking or consuming food.
4. Fire Prevention and Protection

Spray painting presents varying degrees of fire hazards, depending on

the materials used. Any material having a flash point below 140°F should
be handled very carefully, and this is applicable to those having a flash
point higher than this.
5. Fire Fighting
Portable fire extinguishers should be installed near all areas where spray
painting is carried out.
6. Ventilation Systems
If spray painting work is undertaken in a confined space adequate

Ventilation should provided. Mechanical ventilation shall be in operation
while spraying operations are being conducted and for a sufficient time
thereafter to assure vapors are completely exhausted. Adequate
conditioned make-up air must be provided.
The quantity of paints, lacquers, thinners, solvents and other flammable

and combustible liquids kept near spraying operations should be the
minimum required for such operations.
Bulk storage of these liquids shall be in a separate building detached

from other buildings or in rooms specifically designed and constructed to
meet flammable storage room requirements.
No storage of open containers of solvents is permitted. Open containers

may only be used for cleaning of painting materials after which the
solvent should be transferred back to a closed container for retention or
disposal.
Supplies of flammable and combustible liquids should be stored in

approved fire-resistant safety containers equipped with flash screens and
self-closing lids.
Original closed containers, approved portable tanks, and approved safety

cans should be used for bringing flammable or combustible liquids into
spray finishing rooms. Open or glass containers shall not be used.
The withdrawal of liquids from containers and the filling of containers,

including portable mixing tanks, should be done only in a mixing room or

in a spraying area when the ventilating system is in operation.

Precautions shall be taken to protect against liquid spillage.
Whenever flammable or combustible liquids are transferred from one

container to another, both containers shall be effectively bonded and
grounded. This practice prevents electrical discharge from the
accumulation of static charge.
Precautions to be taken during installation of electrical fittings are given

elsewhere.
While using airless spray guns adequate precautions to be taken as

recommended by the manufacturer.
It is desirable that the floor of paint spray booths be covered with a non-
combustible mat, removable for cleaning or disposal.
Pressure hoses and couplings shall be regularly inspected for condition

and shall be replaced as needed.
When positive displacement pumps are used, a relief valve shall be

installed in the discharge line to prevent overpressure.
The same general safety and health precautions apply to spray painting
from pressurised cans as to spray painting by other means.

15. Hand Tools and Power Tools
Introduction
Hand tools and power tools enable employees to apply additional

force and energy to accomplish a task. These tools improve
efficiency and make better products. Because of increased force of
hand and power tools, the object of safety with these tools is to
protect users from inflicting harm to themselves and others as well
as to provide ergonomically designed tools. Each year hand tools
account for about 6% of all disabling injuries. Through proper
selection, use, care, maintenance and supervision of hand and
power tools, injuries from tools can be prevented.
In selecting hand and power tools, management should consider

use, comfort, quality, vibration, noise, and stress factors. To
determine if tools should be changed, take into account employees’
concern about the tool, associated accident and injury rates, work
methods, setup of workstations, and trends for any particular task.
Certain changes may include adding personal protective equipment,
job rotation, or other adjustments.
Five safety practices can help to eliminate or greatly reduce injuries

with hand and power tools:
1. Provide proper protective equipment.
2. Select the right tool for the right job.
3. Keep tools in good condition.
4. Train workers to use tools correctly.
5. Store tools in a safe place.
Central tool controls Programme ensure uniform inspection and

maintenance of tools by trained employees.
Toolbox includes portable boxes, tool chests, mobile tool cabinets

and gang boxes. These items should be used only for storing tools
or lunch boxes. Make sure toolboxes and cabinets are locked after
each workday and that all tools are accounted for.
Hand Tools And Power Tools 1

A good maintenance and repair program includes tool control

through periodic inspection of all tool operations (See annexure–1).
Make sure employees have adequate workspace and equipment for
repairs. Only tools that are not chipped, battered, or mushroomed
should be redressed otherwise they should be discarded. Handles
should be properly attached to tools and fitted by an experienced
worker.
Misuse of common hand tools such as screwdrivers, hammers,

punches, cutting tools, tap and die tools, saws, files, hand snips
and cutters, wood chisels, axes, hatchets, knives, shovels and
takes is a source of many injuries. Supervisors may mistakenly
assume that everyone knows the proper use of common hand tools.
Make sure workers are trained in safe work habits and do not
attempt to use tools for jobs they were not designed to do.
The most common types of wrenches used in industry. Include

open end, box and socket, combination, torque, adjustable and
pope wrenches. Workers must be alert for the possibility of a
wrench slipping off the fastener, the fastener suddenly turning free
the wrench breaking, or a fastener breaking. Wrenches should be
inspected frequently for cracks, flaws or wear. Workers should
exercise similar precautions when using tools such as tongs, pliers,
special cutters and pullers.
Soldering irons can be the source of burns and illnesses that result
from inhaling fumes. Soldering irons must have adequate holders to
prevent accidental burns and workers have proper protective gear
and ventilation to eliminate vapor and fume hazards.
• Portable power tools are divided into five groups: electrical,

pneumatic. Gasoline, hydraulic and power-actuated mobility and
power sources. Safe work practices include disconnecting the
power before changing accessories, storing tools properly, wearing
protective gear and following manufacturer-operating rules.
Workers should be trained to select the right tool for the job and
should frequently inspect and repair equipment.

• The risk of electrical shock from electrically powered tools can be

reduced by using battery-operated tools, properly grounding
equipment, and using only approved wiring and current. Tools
used in wet locations should be provided with a ground-fault circuit
interrupter. Double-insulated tools also provide more reliable shock
protection without third-wire grounding.
• The most common electrical tools include drills, circular saws

reciprocating saws, miter-box and shop saws, stationary band
saws, jig/saber saws rotary die grinders, grinding wheels, buffers
and wire brushes, sanders and routers. Workers must recognize
and protect themselves from shock, noise, cuts burns and other
potential hazards by using proper guards and safety equipment and
devices. All parts of electrical equipment should be inspected
regularly.
• Air powered tools include air hoses, grinders and pneumatic impact
tools. To prevent injuries associated with air hoses, workers should
make sure hoses do not present tripping hazards, avoid using
hoses as cleaners and prevent accidental disconnection of hoses
from the tools. Air-powered grinders require the same type of
guarding as electrical grinders.
• Pneumatic impact tools (nailers, drills, impact wrenches, etc.)

require two safety devices; an automatically closing valve and a
retaining device to hold the tool in place to prevent it from being
fired accidentally. Workers must check noise levels to determine if
hearing protection is needed and guard their eyes against flying
debris.
• Special power tools include hydraulic, gasoline powered and powder

actuated equipment. Hydraulic tools cause injuries because high-
pressures leaks or ruptures in hoses may force oil under the skin of
workers hands or arms.
• Gasoline powered and powder actuated tools present serious

hazards and must be operated only by trained personnel and
adequately guarded to prevent fires and injuries. Similar

precautions are used for impact wrenches as for any electrical or

hydraulic equipment.
• Workers operating power tools must dress appropriately to avoid

catching clothing or jewelry in the equipment, wear safety shoes,
use fall protection equipment when working in overhead places,
wear respirators on buffing, grinding and sanding jobs, and eye and
hearing protection where appropriate.
• Some does and don’ts using power tools are listed in Annexure – 2.
• Some of the common personal protective equipment’s required are

listed in Annexure - 3

Annexure – 1
PORTABLE ELECTRIC TOOLS
Inspection Checklist
GENERAL
Low voltage or battery powered equipment used in

tanks and wet areas? Yes /No
Tools well maintained? Yes /No
Motor in good condition? Yes /No
Approved tools used in explosive atmospheres? Yes /No
Tools left where they cannot fall? Yes /No
CORDS
Insulation and plugs unbroken? Yes /No

Cords protected against trucks and oil? Yes /No
Cords not in aisles? Yes /No
GROUNDING
Ground wire fastener in safe condition? Yes /No

3-wire plug extension cord (if a 3-wire tool)? Yes /No
Ground wire used? Yes /No
Defects or minor shocks reported? Yes /No
Ground fault circuit interrupter used? Yes /No
GUARDING
Guards used on grinders and saws? Yes /No

Movable guards operate freely? Yes /No
Eye or face protection worn? Yes /No
A model check list is given to enable supervisory personnel to inspect the

tools before issue and on their return back to stores

Annexure - 2
Tool Safety a movement hits full strides for accident prevention.
- Taking Tools For Granted

Is Inviting Accident.
- Familiarity Breeds
Injuries
- Before you begin,

grab the unsafe condition
and practices share it off with
safety procedure manual.
- Using tools improperly can cause

serious physical truma.

General Safety Precautions
1. Secure work with clamps or a vise, freeing

both hands to operate the tool.
2. Avoid accidental starting. The user should
not hold a finger on the switch button while
carrying a plugged in tool.
3. Proper apparel should be worn; loose
clothing, ties, or jewelry can become
caught in moving parts.
4. Work area should be well lighted.
5. Be sure to keep good footing and maintain good balance.
6. The employers is responsible for the safe condition of tools and
equipment used by employees but the employees have the
responsibility for properly using and maintaining tools.
7. Never apply unnecessary pressure when using tools.
8. Always cut away from your body.
A. Hand Tools:
1. All tools and Equipment (Both company and employee owned) used
by employees should be in good condition.
2. Hand tools such as chisels, punches wedges or drift pins which
develop mushroom heads during use, it's heads might shatter on
impact, sending sharp fragments flying should be recondition or
replaced.
3. Broken, loose, splintered or fractured handles on hammers, axes and
similar tools, the head of the tool may fly off and strike the user or
another co-worker. Tool handles should be replaced promptly and
wedged tightly in the head of all tools.
4. Worn, bent or sprung jaws spanners and wrenches, which slip during
use, should be replaced regularly.
5. Appropriate handles should be used so the operator's wrist can
remain in a natural position for files and similar tools. (Selection
depends on the relationship between the work surface height and
operators elbow height.)
6. Employees to be made aware of the hazards caused by faulty or
improperly used hand tools.

7. Appropriate safety glasses, face shields etc. should be used while

using hand tools for equipment which might produce flying
materials or be subject to breakage.
8. Jacks should be checked periodically to ensure that they are in
good operating condition.
9. Tool cutting edges should be kept sharp so the tool will move
smoothly without binding or skipping. Blunt tools can be more
hazardous than sharp ones.
10. Tools should be stored in dry, secure locations were they won't be
tempered.
11. Eye or face protection should be used when
driving hardens or tempered spuds or nails.
12. Floor near work area should be kept as clean
and dry as possible to prevent accidental
slips while working with or around dangerous
hand tools.
13. Scattered tool near work place should be
avoided.
14. Always pull on the wrench. Never push
against it.
15. Whenever possible use a box-end wrench
instead of an open-end wrench to avoid
slipping.
16. Around flammable substances, sparks
produced by Iron and Steel hand tools can
be a dangerous ignition source. Where this
hazard exists, spark resistant tools made
from brass, plastic; aluminum or wood will
provide safety.
B. Power tools:
1. Majority of power tool accident is caused by

improper handling and poor maintenance of
equipment.
2. Power tools should be used with the shield,
guard or attachment that is recommended
by the manufacturer for particular type of
job to prevent physical contact.

3. Portable circular saws should be equipped

with guards above and below the base
shoe. They are not wedged up with the
lower portion of the blade unguarded.
While cutting always use push sticks,
don’t use your hands.
4. All cord-connected, electrically operated
tools equipment should be effectively
grounded by using three-cord wire or the
approved double - insulated type.
5. Effective guard should be in place over
belts, pulleys, chains, and sprockets, on
equipment such as concrete mixtures and
air compressors.
6. Hoisting equipment should be available
and used for lifting heavy objects and
hoist ratings and characteristics should be
appropriate for the task.
7. Earth leakage circuit breakers (ELCB)
should be provided on all temporary
electrical 15 and 20 amp circuits should
be used during periods of construction.
8. Pneumatic and hydraulic hoses on power
operated tools should be checked
regularly for deterioration or damage.
9. Never carry a tool by the cord or hose.
10. Never yank the cord or the hose to
disconnect it from the receptacle.
11. Keep cords and hoses away from heat, oil
and sharp edges.
12. Disconnect tools when not in use, before
servicing and when changing accessories
such as blades, bits and cutters.
13. All observers should be kept at a safe
distance away from the work area.
14. All portable electric tools those are
damaged shall be removed from use and
tagged "DO NOT USE".

15. Electric tools should be operated within

their design limitations.
16. Gloves and safety footwear are
recommended during use of electric tools.
17. When not in use, tools should be stored
in a dry place.
18. Electric tools should not be used in damp
or wet locations.
19. Never temp to use two-hole receptacle by
removing third prong provided for
earthing of tool from the plug.
20. Portable electric tools should be used
generally of 10V single-phase
transformer with center tap earthed.
21. Portable electric tools should be tested
before put into use.
22. Possible tools like drills, grinders, sanders pneumatic chisel are of
good quality and the tools reach are attached to machine properly
and locked before put to use.
23. Unless a person is authorized, he should not operate, repair or
test any equipment.
24. Drills should be fastened to paving breaker to prevent its flying.
25. Grinding wheels should be inspected before mounting. It is to be
checked for maximum operating speed against the machine
speed. Guard to at least half of the wheel diameter should cover
wheels. The operator should wear goggles while grinding.

Annexure – 3
Personal Protective Equipment
Workers using revolving tools such as drills saws and grinders should not
wear ties, gloves loose clothing and jewelry. Clothing should be free of
oil, solvents or frayed edges to minimize the fire hazard from sparks.
The weight of most power tools makes i9t advisable for users to wear
safety shoes to reduce the chances of injuries should the tools or work-
piece fall or be dropped.
When power tools are used in overhead places, the operator should wear
fall-protection devices to minimize the danger of falling, should be tool
break suddenly or shock the operator or should the operator slip. Also,
attach a safety line to the tool to keep it from falling on persons below
should it be dropped.
On buffing, grinding and sanding jobs that produce harmful dusts provide
workers with approved dust-type respirators. For operators of powder-
actuated tools or hammers, provide hearing protection if more positive no
controls are possible.
In all operations where striking and struck tools are use or where the
cutting action of tool causes particles to the provide eye protection that
conforms to ANSI Z87.1 Practice for Occupational and Educational Eye
and False Protection. Minimize the hard of flying particles by using
nonferrous, soft striking tools and shielding the job site with metal, wood
or canvas. However, eye protection still required.
Wear eye protection or face shields when using wood working or cutting
tools such as chisels, brace and bits planes scrapers and saws. There is
always the chance of particles falling or flying into the eyes. Also wear
eye protection or face shields when working with grinders buffing wheels
and scratch brushes. The unusual positions in which the wheel operates
may cause particles to be thrown off in all directions. For this reason,
eye protection is even more important than it is when working with
stationary grinders.

Do not overlook eye protection on the following jobs:
• Cutting wire and cable

• Striking wrenches
• Using hand drills
• Chipping concrete
• Removing nails from lumber
• Shoveling material
• Working on the leeward side of a job
• Using wrenches and hammers overhead
• Working on other jobs where particles of materials or debris may fall.

Annexure – 4
Hand Tools Safety
Taking tool for granted is inviting accident. Hammers, wrenches, chisels,

pliers, screwdrivers, and other hand tools are often underrated as
sources of potential danger. Hand tools may look harmless, but they are
the cause of many injuries. In fact, an estimated 8 percent of all
workplace compensable injuries are caused by incidents associated with
hand tools. Also familiarity breeds injuries. These injuries can be serious,
including loss of fingers or eyesight.
To avoid injuries, remember the following safety procedures:
Do’s
1. Work area must be well lighted.
2. Always cut away from your body.
3. Avoid scattered tool near work place.
4. Pass a tool to another person by the handle.
5. Use the right tool in the right size for the job.
6. Always pull on the wrench. Never push against it.
7. Be on the lookout for signs of repetitive stress. Early detection
might prevent a serious injury.
8. Keep floor area clean and dry to prevent accidental slips while
working with or around dangerous hand tools.
9. Carry tools securely in a tool belt or box. Use a hoist or rope.
10. Make sure your grip and footing are secure when using large tools.
11. Check jacks periodically to ensure that they are in good condition.
12. Secure work with clamps or a vise, freeing both hands to operate
the tool.
13. Keep close track of tools when working at heights. A falling tool can
kill a co-worker.
14. Select ergonomic tools for your work task when movements are
repetitive and forceful.
15. Replace or redress tools heads that might shatter on impact
sending sharp fragments flying.
16. Store tools in dry and secure locations were they wouldn’t be
tempered when you stop work.

17. Use the right personal protective equipment (PPE) for the job.
Follow L & T’s safety manual for selecting and using safety
eyewear, steel toed shoes, gloves, hard hats, etc.
Don’ts
1. Don't carry tools up ladders.
2. Never toss tools to another person.
3. Never apply unnecessary pressure when using tools.
4. Don't use your wrench as a hammer & screwdriver as a chisel, etc.
5. Never carry sharp or pointed tools such as a screwdriver in your
pocket.
6. Don’t use worn, bent or spung jaws spanners and wrenches that
may slip during use.
7. Don't use broken, mashroom head or damaged tools, dull cutting
tools, or screwdrivers with worn tips.
8. Never use blunt tools, which is more hazardous then sharp tool as
sharp cutting edge move smoothly without bending or skipping.
9. Never use tools having broken handle. Replace handles promptly
and wedged tightly in the head of the tool. As that may fly off and
strike the user or another co-worker.
10. Never use iron and steel hand tools which produce sparks around
flammable substances. Use spark resistant tools made from brass,
plastic, aluminum or wood.
By following these precautions, you can help prevent injuries and provide
a better workplace for everyone.
Hand tools can cause many types of injuries:
1. Cuts, abrasions, amputations, and punctures. If hand tools are

designed to cut or move metal and wood, remember what a single
slip can do to fragile human flesh.
2. Repetitive motion injuries. Using the same tool in the same way all
day long, day after day, can stress human muscles and ligaments.
Carpal tunnel syndrome (inflammation of the nerve sheath in the
wrist) and injuries to muscles, joints and ligaments are increasingly
common if the wrong tool is used, or the right tool is used
improperly. Injury from continuous vibration can also cause
numbness or poor circulation in hands and arms.

3. Eye injuries. Flying chips of wood or metal are a common hazard,

often causing needless and permanent blindness.
4. Broken bones and bruises. Tools can slip, fall from heights, or even
be thrown by careless employees, causing severe injuries. A
hammer that falls from a ladder is a lethal weapon.
Remember, an ounce of prevention is worth a pound of cure!
Power Tools Safety
Power tools are handy helpers that people use for a variety of purposes in
all settings. They come in different styles and sizes. These tools are
useful time savers, but they're also deceptive. They can deliver a
paralyzing, or even deadly shock. They can slash, cut and mangle,
sometimes easier than larger, stationary machines.
Do’s
1. Keep cords away from heat, oil and sharp edges.
2. Choose the right tool for the job; inspect it for damage and
adjustment and make sure all guards are in place.
3. Disconnect tools when not in use, before servicing and when
changing accessories and locked before put to use.
4. Operate electrical tools within their design limitations and test them
before putting into use.
5. Be sure switches are in the off position before you plug tools into an
outlet.
6. Make sure the power tool has stopped running before placing it on
the ground or a surface that you're working on.
7. Always check the condition of cords for deterioration or damage.
8. Keep fingers well away from switches or buttons when tools are not
being used, and unplug or deactivate tools not in use. A power tool
can be turned on accidentally, penetrating a hand, arm or leg.
9. Use proper PPE - such as safety glasses when cutting, a dust mask
when creating dust and hearing protection when noise levels are
high.
10. Keep all observers at a safe distance away from the work area.
Remove from use all portable tools those are damaged and tagged
“DO NOT USE”.
11. Only 3-prong grounding extensions are to be used for equipment
and plugs must be matched with outlets.

12. When working in wet areas or areas that contain flammable liquids
use only specified approved tools.
Don’ts
1. Don’t wear loose clothing, ties or jewelry that can be caught in

moving parts.
2. Don't unplug or plug equipment with wet hands and use in damp or
wet locations.
3. Don't unplug power cords by pulling on the cord, or raise or lower
the equipment by the cord.
4. Never tempt to use two-hole receptacle by removing third prong
provided for earthing of the tool from the plug.
5. Power tools should never be pointed at anyone, even in fun or
when unplugged. There is no excuse for fooling around with
potential danger in the workplace.
6. Don't use cord for dragging tools on the floor, or fasten them with
staples, nails or other means that could damage them. This can
damage the cord and cause the tool to short when reconnected.
7. Don’t operate, repair or test any equipment by unauthorised
person.
It's easy to forget the potential dangers of power tools because they are
usually small, portable and commonly found around the shop. Many times
they're not treated with enough respect, and they are frequently left lying
around in unsafe places.
We should be as careful with power tools and portable electric tools as we

are with any other dangerous machinery. Review and remember the
following precautions:
Power tools are invaluable, timesaving devices when used properly, but
careless or improper use can cause severe injury or death. Always follow
safety instructions when operating power tools
The Power is in Your Hands - Use It Safely!

Annexure – 5
Pneumatic Tools Safety
Air powered tools present many of the same hazards as their electrically
powered counterparts, Electrical tools are powered from a source that
provides a well-regulated standard current. However, with air powered
tools, air may be delivered at varying pressures, flows and plus hazards
you may not have considered. Here are things to remember when using
air tools:
Do’s
1. Adjust your air pressure to the manufacturer's rating.
2. Make sure hoses are of the correct inside diameter and are not kinked
or crushed.
3. Your compressor and receiver must have enough capacity to deliver
air in an amount sufficient to properly operate all attached tools.
4. Installed effective mufflers on the air exhaust at the tool itself or
nearby or worn hearing protection from prolonged exposure to muffled
loud noise of pneumatic tools can be much noisier than electric tools.
5. Frequently wipe both your hands and the tool, if oil-contaminated air
discharges near where you grip the tool.
6. Use hand gloves to avoid frostbite, stiffen your fingers, or even make
you more susceptible to certain types of cumulative trauma injuries by
cold air discharges on your hand.
7. Protect the hose from physical damage, as you may injured by
violently whipping air hose around or while scrambling to get out of its
way until the air is shut off.
8. Use goggles to protect your eyes from compressed air or particles may
fly from equipment such as chipping hammers, rock drills, rotary drills
or sanders, which cause pain or injury.
Don’ts
1. Avoid over oiling the tools.

2. Don’t exceed the pressure/flow then the manufacture’s rating, the tool
itself could over-speed, delivering too much torque or other excessive
force breaking tool or work piece.

3. Don’t give inadequate pressure or flow which result in an under

performing tool. This may prompt you to apply excessive force in your
work, possibly causing tool breakage and injury.
4. Don’t work in confined or poorly ventilated spaces, as the air feeding
the tool may contain oil or antifreeze, discharging contaminated air
into the environment around you.
5. Don’t work in the immediate work area having live electric power, you
can get a shock as air powered tools are not grounded or double
insulated.

16. Handling of Chemical / Hazardous Substances
Great many chemical substances are used in construction - there is

hardly a site without them. They are found in adhesives cleaning
agents for brickwork and stonework, decorative/protective
treatments for timber and metals, floor treatments, fungicides,
cements and grouts insulants, sealant, paints, solvents and much
else. Of particular importance are solvents, which are liquids
commonly, used in paint strippers, lacquers, varnishes, surface
coatings, thinners and similar cleaning materials.
Chemicals and their risks:
Many chemicals are hazardous, with a potential for fire and

explosion, or toxic, with an inherent potential to cause poisoning.
Toxic substances cause both acute effects, such as dizziness,
vomiting and headaches, produced in a short time by exposure to
solvents, and chronic effects resulting from exposure over a long
period as in lung diseases such as asbestosis and silicosis.
Contact dermatitis may result from the contact between the skin
and some chemicals. Acids and alkalis are corrosive and can
damage both skin and eyes.
Entry into the body
A chemical can cause injury in various ways depending upon

whether it is solid or liquid, the form of airborne dust, vapour,
fumes or gas.
The routes into your body are by:
Inhalation or breathing in:
This is the most important route of entry. Some toxic gases and
vapours cause irritation in the nose and throat and so give warning
of their presence others do not, and penetrate to the lungs or blood
Handling of chemicals / Hazardous substances 1

stream. It is the smallest dust particles, those not visible to the

naked eye, which reach furthest into the lungs. Inhaled dust
accumulates in the lungs, producing changes and causing an
incurable disease called ” pneumoconiosis ". Breathlessness and
inability to work are the eventual consequence. Some dusts such
as quartz and asbestos destroy the lung tissue and may lead to the
development of tuberculosis or cancer.
Ingestion or swallowing:
This is Possible when You handle chemicals such as lead-based

paints and then eat or smoke without first washing Your hands,
when toxic vapours contaminate cups, plates or eating utensils, or
when you eat meals at the work site.
Absorption through the skin:
Some solvents can be absorbed through the skin into the blood
stream and may travel to internal organs such as the brain and
liver.
Contact Dermatitis:
Contact Dermatitis or eczema frequently results from the contact

between the skin and some chemicals. Acids and alkalis are
corrosive and can damage the skin and the eyes on contact. Unless
large amounts of water are used at once to rinse the substance off,
serious burns will be caused.
Preventive measures:
Accidents and ill health from the use of chemicals can be prevented
if we know what chemicals we are using and the risks they pose,
and follow the established safe practice in handling them.
Generally, there is an order of priority in the measures for dealing
with hazardous chemical substances.
• Substitute the chemical with a harmless or less hazardous one.

• Enclose the process using the chemical, or provide other

engineering controls such as exhaust ventilation; this is often
difficult in construction processes.
• Use personal protective equipment (PPE).
If the use of hazardous chemicals cannot be avoided, the following

are some basic safety measures that can be adopted:
- The containers of chemicals should be kept in a separate and

secure store.
- Because two containers look the same, it should not be

assumed that they contain the same material.
- There should be a label on the container, if there is no label,

then it should not be used.
- The people should understand the contents of the label and if it

is not difficult to understand what it says, then the instructions
should be followed.
- If the information is not sufficient to tell how to handle the

chemical safely, the employee should seek clarifications from
the supervisor (with the help of the chemical safety data sheet
available with him). If no such clarification is available, the
worker should not use the chemical.
The correctness of the PPE given should be checked before their

use.
- When opening containers, care should be taken to avoid

spillage of the contents of containers.
The worker should avoid breathing in any fumes from chemicals.

Provision of good ventilation, or working in the open will reduce the

hazard. The worker should leave the work area immediately if he

feels dizzy or unwell.
- Impermeable clothing should be worn If large quantity of

solvent is used. Clothing wetted by solvents should be
removed and dried in the open.
- Requisite quantity of chemicals alone should be stored and

used.
- Eye protection should be worn when chemical are being moved

or transferred on site.
- When mixing or pouring chemicals using temporary containers,

lllit should be properly labelled.
- Workers should be encouraged to wash before you eating and

smoking at the workstation.
- If the skin is splashed with a chemical, it should be rinsed

immediately with plenty of clean running water. Eyes should
be flushed out thoroughly with water and should receive
immediate medical attention.
- If the worker is burnt by chemical, or feel unwell after using

Chemical, seek medical attention without delay.
- If there is a spillage of chemicals on the ground or floor, this

should be reported so that the right action can be taken, such
as soaking it up with dry sand.
Highly flammable chemicals:
Many chemical substances used in construction are highly

flammable as well as toxic. The following precautions should be
followed when handling or using them:

- Study the label and the instructions on the chemical safety

data sheet about safe handling and first aid measures.
- Remember that all flammable liquids give off vapours which

travel unseen into the air and are easily ignited. Never smoke
if there are flammable chemicals in the area. Find out what
action to take in the case of fire.
- Keep containers in the store until required for use, and return
them there when you have finished with them. Store drums
upright.
- Treat empty drums with as much care as full ones - they will
still Contain flammable vapour.
- Always transfer the contents of large containers to small

containers in the open.
- Use funnels and spouts to prevent spillage. Soak up any

spillage with dry sand and remove the contaminated sand to a
safe place in the open air.
- If you cannot avoid using highly flammable liquids in an

enclosed area, make sure there is an adequate supply of fresh
air. This can usually be achieved by opening windows and
doors to the full. If it is necessary to use a fan, check that the
fan is electrically safe to use in a flammable atmosphere.
Hazardous substances:
Cement:
Cement mixes are a well-known cause of skin disease. Both irritant

and allergic contact dermatitis can result from proximity to wet
cement. Prolonged exposure to wet cement (for example, if you
kneel or stand in it) may cause cement burns or ulceration of the
skin.

The following precautions should be taken:
- Avoid breathing in cement dust, as well dust created by the

surface treatment of hardened concrete which may contain a
high silica content, by wearing suitable respiratory protective
equipment.
- Protect the skin from contact by wearing long-sleeved clothing

and full-length trousers, with rubber boots and gloves when
required.
- Protect the eyes., if any cement gets into the eyes, rinse them
immediately with plenty of warm water.
- Immediately wash off any dust or freshly mixed cement that

gets on to the skin.
- Clean off your clothing and boots after work.
Asbestos:
Breathing in asbestos dust can kill by causing irreversible lung

damage and cancer. There is no known cure for asbestos-related
diseases. The more asbestos dust breathed in, the greater the risk
to health. There are control limits for the various types of
asbestos. Asbestos is used in the following situations:
(a) Asbestos insulation or coating is used for:
(i) Thermal insulation of boilers;

(ii) Fire protection of structural steelwork;
(iii) Thermal and acoustic insulation of buildings.,
(b) Asbestos insulating board is used in a wide variety of places

such as:

(i) Fire protection on doors, protected exits, structural

steelwork, etc.;
(ii) Cladding on walls, ceilings, etc.
(iii) Internal walls and partitions
(iv) Ceiling tiles in a suspended ceiling;
(c) Asbestos cement is applied on:
(i) Corrugated sheets (roofing and cladding of buildings)

(ii) Flat sheeting for partitioning, cladding and door
facings.,
(iii) Gutters and down pipes.
Before starting work:
If it is not clear whether insulating material, boarding, and so on

contain asbestos, bulk sampling and laboratory analysis are
necessary. Someone must do this with suitable training and
experience. Alternatively, we may assume that the material
contains crocidolite (blue), amosite (brown) or chrysotile (white)
asbestos and take appropriate precautions.
Before starting any work with asbestos, an adequate assessment

must be made to work out the precautions needed to control the
exposure to the substance. Work with asbestos may range from
cleaning brake drums of construction plant and vehicles to full-scale
asbestos removal.
Carrying out work with asbestos:
In many countries those who work with asbestos to any extent, and
in particular in removing and disposing of asbestos, require to be
licensed or to hold a permit. In working with asbestos insulation
board, workers will probably need to wear suitable protective
clothing. Only working methods that keep asbestos dust levels as
low as possible should be used (e.g. use hand tools and avoid
breaking boards).

Asbestos cement is less likely to generate dust than many other

asbestos products, but the risk of asbestos dust release is still
present.
When cutting asbestos cement, use hand tools (or power tools
fitted with exhaust ventilation equipment). Where it is not possible
to keep asbestos dust levels under control limits, respirators should
be worn. Protective clothing will probably be required for any
significant work with asbestos cement. If you have to clean
asbestos cement sheeting encrusted with lichens or mosses, a
system of wet scraping/brushing is preferred.
Methods of limiting exposure to asbestos dust include:
- Removing asbestos materials before starting major demolition

work. This prevents accidental exposure to asbestos "
- Wet methods of removal (to suppress dust);
- Prompt removal and bagging of waste asbestos, and disposal

at an approved waste disposal site.
- Separating asbestos work areas from other general work

areas.
Lead:
Inorganic lead is found in many construction products, e.g.

electricity cables, pipes, gutters and old lead sheet roofs. Organic
lead is added to motor fuels, and storage tanks will be heavily
contaminated.
There is a risk to health from inhaling dust or fumes created by

burning or cutting materials containing lead, including painted
surfaces, by welding, by grinding or cutting, and by spray painting
of leaded paints. Lead can be absorbed when swallowed, usually

when food is contaminated, and adequate washing facilities should

be provided. Organic lead compounds are readily absorbed through
the skin.
Excessive lead absorption causes constipation, abdominal pain,

anaemia, and weak muscles and kidney damage. It can also affect
the brain, causing impaired intellect, strange behaviour, fits and
coma. If lead is used in any form, the following precautions are to
be taken:
- Hands should be washed regularly and always before eating,

and smoking.
- Protective clothing and respiratory protective equipment

should be provided whenever lead levels exceed national
control limits.
- Wear works clothing on the job and store your “street"

clothing where it cannot be contaminated by your work
clothing.
Material Safety Data Sheet:
Apart from the most common materials listed above, the site uses
many other chemicals with varying quantities during construction
and commissioning of the project. Listing all the details of all these
chemicals in this manual is not practicable.
An effective way of protecting the plant and machinery and people

from the harmful effects of these chemicals is to procure the
material safety data sheet of them from their manufacturers and
use / refer before handling, storing and transporting any of these
materials.
The material safety data sheet, referred as MSDS, is a

comprehensive document provided by the manufacturer of the
chemicals for reference for of the user, detailing their Physical,

Chemical (Toxicity, Flammability and Reactivity) properties and the

remedial measures to be taken in the event of a spillage,
contamination, explosion and fire.
The user should familiarise with the details and equip himself to
tackle any of the emergency listed in the MSDS.
The MSDS of some of the commonly used chemicals, acid and alkali
is given in the annexe.

17 Fire Prevention
Introduction:
Fire is the most effective destroyer of plant and machinery and

crores of rupees are loss every year due to fire. Hundreds of
people lose their lives due to fire every year.
In order to prevent its occurrence, it is essential to know the

techniques of the protection, fire prevention and control measures
and fire fighting.
Fire Protection:
• Fire protection includes procedures for preventing, detecting

and extinguishing fires to protect employees and property
and to ensure continued operations. To accomplish these
goals, companies must develop fire protection programs.
• The primary purpose of the program is to prevent fires from

starting and to train employee in proper procedures should a
fire break out. Employees should know their roles in
detecting a fire and in transmitting an alarm, evacuating a
building, confining the fire, and extinguishing the fire.
Although a totally safe system for protecting life is not
achievable, fire protection programs should enable
companies to reduce hazards significantly.
• Fire protecting engineering is a highly developed

specialization requiring special engineering disciplines.
Achieving the most efficient fire protection system require
the involvement of architects, interior designers, urban
planners, building contractors. Electrical and structural
engineers, fire detection-system manufacturers, building
safety engineers, and local fire departments.
Fire Protection Program
The primary purpose of such a program is to prevent fires from

starting. If, nonetheless, a fire does start, employees should know
their role in the following procedures:
Fire Prevention 1
1. Immediately detecting the fire and promptly transmitting an

alarm.
2. Initiating evacuation of the building
3. Confining the fire
4. Extinguishing the fire
Objectives of a Fire Protection Program
When planning a fire-protecting program first make a statement of

objectives for fire safety. Objectives might be stated in terms of
safety to people and of allowable downtime for the plant. Fire
protection systems must meet or exceed all codes and should be
especially protective of areas in the plant that are viral to the
continuity of its operation. When designing the plant’s building and
laying out its operations, incorporate greater measures of fire
safety than are called for.
Architects and engineers must realize that designing for fire

protection is a legitimate part of their responsibilities. They must
understand (1) the special thermal load that fire puts on structural
parts of buildings, and (2) the preventive measures that can be
incorporated into their designs. The earlier that fire-safety
objective is identified and design decisions are made, the more
effective the fire protection system can be.
Some general facts about fire protection that must be kept in mind
follow:
• No facility is absolutely fireproof. Nearly everything can
burn, given ignition, adequate fuel and sufficient oxygen.
• Heat energy is transmitted by convection, conduction and
radiation.
• Fire and flame will spread in a building both vertically and
horizontally.
• The spread of the heat, smoke and toxic gases is possibly the
greatest single danger to life and takes place in much the
same manner as does the spread of fire. Smoke and toxic
gases are responsible for 66% of deaths from fire in
buildings.
• Onsite early detection of a fire is absolutely essential.
Fire Prevention 2
• The use to which a building is put its occupancy will influence

the degree of fire hazards. The more hazardous the materials
handled in a plant area, the more likely is the chance for the
fire to start and rapidly spread.
• The contents of a building are usually a more important
factor in the start of a fire than is the physical structure of
the building.
• Very often, there are only a few minutes between the
beginning of combustion and the development of a
destructive fire.
• What happens or doesn’t happen, in the first few minutes of
a fire determines whether it can be controlled or not.
• A fire is usually (1) controlled by built-in equipment, and or
(2) put out by Fire Fighters.
• Every fire protection device involves compromise. That is, a
fire protection system always represents some trade-off-
involving cost, reliability, or safety. Some risk will be some
loss. The optimum level of fire protection is that which
minimizes the cost from expected fire losses. (See the
section Fire Risks, later in this chapter).
• The cost of fire protection should have a corresponding effect
in reducing the amount of loss or risk involved.
• An automatic sprinkler system is the best tool to reduce loss
of life from fire.
• People and their actions are key elements. Probably more
than half of all fire losses is the result of human mistakes
resulting from inadequate training, insufficient motivation, or
improper action.
• Construction alone is not adequate protection insofar as life
safety is concerned.
Fire Prevention
Complete steps to be taken for the prevention of fuel are

extensive. The Planning stage itself all the statutory provisions
should be in corporate.
To be effective knowledge of the chemistry of fire is essential.
Fire Prevention 3
The Chemistry of Fire
Fire, or the process of combustion, is extraordinarily complex. For

a fire to occur, fuel oxygen, heat and a chemical chain reaction join
in a symbiotic relationship ( Figure 6-6). In combustion, heat
energy is released in a self-catalyzed reaction involving a
condensed phase fuel, a gas-phase fuel or both. The combustion
process is usually associated with rapid oxidation of a fuel by
oxygen in the air. If the combustion process is confined so
pressure can increase, an explosion can result. A similar process
that takes place over long periods of time and at a lower
temperature is called oxidation. Rusting of metal is an example of
this. A fire then, is a combustion process intense enough to emit
heat and light.
In addition, a fire can be classified into two general forms or modes

flames fire and surface fire. Flame fires directly burn gaseous or
vaporized fuel and include deflagrations. The rate of burning is
usually high, and a high temperature is produced. The following
are two types of flame fires:
• Premixed flame fires exist in a gas burner or stove and are

relatively controlled.
• Diffusion flame fires refer to gases burning on mixed vapors
and air. Controlling these fires is difficult. Surface fires occur
on the surfaces of a solid fuel and are often called a glow or
deep embedded seated fire. Surface fires take place at the
same temperature as do open flame fires. The surface fire is
represented by the fire triangle-heat, fire and air, but no
chemical chain reaction. The flame fire includes chemical
chain reaction. These two modes of fires are not mutually
exclusive and they may occur together or alone.
Knowing how and why a fire burns suggests ways to control and
extinguish it. The surface fire has three components that can be
controlled, while the flame fire has four components. Fires can be
controlled in the following ways:
• Heat can be taken away by cooling.
• Oxygen can be taken away by excluding the air.
Fire Prevention 4
• Fuel can be removed to an area where there is not enough

heat for ignition.
• The chemical reaction of the flame fire can be interrupted by
inhibiting the rapid oxidation of the fuel and the concomitant
production of free radicals, the lifeblood of the flame’s
reaction.
Cooling a Fire
To extinguish a fire by cooling, remove heat at a greater rate than

the total heat that is being evolved by the fire. To do this, the
cooling agent must reach the burning fuel directly. The cooling
action may also stop the release of combustible vapors and gases.
The most common and practical extinguishing agent is water
applied in a solid stream or spray, or incorporated in foam. In
practice, the fire is literally drowned into submission by the water.
Removing Fuel from a Fire
Often taking the fuel away from a fire is not only difficult but
dangerous. Fortunately, there are exception (1) Storage tanks for
flammable liquids may be arranged so their contents can be
pumped to an isolated, empty tank in case of fire. (2) When
flammable gases catch fire as they are flowing from a pipe, the fire
will go out if the fuel supply can be shut off. (3) In any mixture of
fuel gases or vapors in air, adding an excess of air has the effect of
diluting the fuel’s concentration below the minimum combustible
concentration point.
Limited Oxygen in a Fire
Limit air, or oxygen, from a fire by smothering the burning area

with a noncombustible material, such as covering it with a wet
blanket (make sure he blanket is not made of highly combustible
fibers), throwing dirt or sand on the fire, smothering it with inert
gas, or covering it with a chemical or mechanical foam.
To be effective, hold the blanket in place long enough for all

smoldering ignition to be extinguished. Further, smothering is
ineffective on substances containing their own oxygen supply, such
Fire Prevention 5
as ammonium nitrate or nitrocellulose. Smothering is also

ineffective on deep-seated materials like wood, rags, and large
rolls or skids of paper.
Covering a fuel, however, can stop a fire. Much foam and some
solids serve as an emulsion film, or cover, on the burning fuel, thus
extinguishing the fire. If the contents of a wastebasket catch fire,
drop an empty wastebasket on top of it to smother the fire.
To dilute oxygen below the concentration necessary to support

combustion, discharge CO2 or another inert gas into the fire. The
fire will then remain out (1) if the percentage of oxygen is reduced
below the level of combustible materials to cool below their ignition
temperature and (2) If no ignition sources are present. Use an
inert gas to purge operations involving flammable vapors and dusts
in confined space where a source of ignition may exist. However,
to ensure that the oxygen concentration remains low enough to
prevent combustion, constantly monitor the flow of inert gas and or
the actual concentration of oxygen.
Interrupting the chain Reaction in a Fire
In analyzing the anatomy of a fire, the original fuel molecules

appear to combine with oxygen in a series of successive
intermediate stages, called branched-chain reactions. Then the
final end product, combustion, occurs. The intermediate stages are
responsible for the evolution of flames.
As molecules break up in these branched-chain reactions, unstable

intermediate products called free radicals are formed. The
concentration of free radicals is the determining factor of flame’s
speed. The life of the free hydroxyl radical (-OH) is very shot,
being on the order of 0.001 of a second, but long enough to be of
vital importance in the combustion of fuel gases. The almost
simultaneous formation and consumption of free radicals appears
to be the lifeblood of the chain reaction.
Extinguishing agents, such as dry chemicals and halogenated

hydrocarbons, remove the free radicals in these branched-chain
reactions from their normal function as a chain carrier. The effects
Fire Prevention 6
that various dry chemical agents such as sodium bicarbonate-base,

potassium bicarbonate base and ammonium phosphate-base and
others have on capturing free radicals depend upon their individual
molecular structure. Potassium bicarbonate dry chemical is the
most effective because of the large size of the potassium ion in the
case of halogenated agents, it is believed that they decompose
when discharged into the fire and form free radicals halogens
(chlorine, bromine or fluorine) that unite with the radicals evolved
in the branched-chain reaction. Again the large halogen molecule
is an effective trap.
Using Extinguishing Agents
Some is extinguishing agents help control fire in more than of

these four causes of fire. For example, both plain water fog (as
compared with straight water streams) and CO2 can react at flame
temperatures with relatively slow-burning free carbon, producing
carbon monoxide (CO), with a resulting decease in black-smoke
production. Because these reaction absorb hear, they lower the
heat of the fire as well as lower the oxygen concentration.
To match the pace of newer and more potent fire extinguishing

agents more sophisticated tactics and technique will be called for.
Although a fire can be attacked from at least four different
standpoints, the use of any one of them does not necessarily result
in the most rapid extinguishing time. A fire can also be attacked
with more than one agent to produce a synergistic effect. This is
done now in the joint use of light water and potassium
bicarbonate-base dry chemical in fighting fires in aircraft crashes.
Although extinguishing fires might sound simple, it is still very far

from being an exact science. Since a fire is usually composed of
more than one source of fuel, it must be fought with several
different extinguishing agents that, by working together,
complement each other. The BIS has developed four classifications
of fuel.
Fire Prevention 7
Classification of Fires
Four general classifications of fires have been adopted by the

NFPA. These classifications are based on the types of combustibles
and the extinguishing agent needed to combat each (See NFPA 10,
Portable Fire Extinguishers).
Class A Fires
Class A fires occur in ordinary materials such as wood, paper,

excelsior, rags and rubbish. The quenching and cooling effects of
water, or first importance in extinguishing these fires. Dry-
chemicals agents (multipurpose dry chemicals) provide both rapid
knockdown of the flames and the formation of a coating that tends
to retard furthers combustion. Where total extinguishment is
mandatory, follow up with water.
Class B Fires
Class B fires occur in the vapor-air mixture over the surface of

flammable liquids, such as gasoline, oil grease, paints, and
thinners. The limiting of air (oxygen) or the combustion-inhibiting
effect is of primary importance to stop fires of this class before
they start. Solid streams of water are likely to spread the fire.
However, under certain circumstances, water-fog nozzles may
prove effective in the control, but not the extinguishment, of these
fires. Generally, use regular dry chemicals, multipurpose dry
chemicals, CO2, foam or halogenated agents for such fires.
Class C Fires
Class C fires occur in or near energized electrical equipment where

non-conducting extinguishing agents must be used. Use dry
chemicals, CO2, or halogenated extinguishing agents for such fires.
Do not use foam or a stream of water because both are good
conductors of electricity and can expose the operators to a severe
shock hazard.
Fire Prevention 8
Class D fires
Class D fires occur in combustible metals such as magnesium,

titanium, zirconium, lithum, potassium, and sodium. Specialized
techniques, extinguishing agents, and extinguishing equipment
have been developed to control and extinguish fires of this type.
Generally, do not use normal extinguishing agents on metal fires.
In such fires, there is the danger of increasing the intensity of the
fire because of a chemical reaction between some extinguishing
agents and the burning metal.
Other Fires
Fire that involve certain combustible metal or reactive chemicals

require, in some cases, special extinguishing agents techniques.
Base upon these classifications various types of portable

extinguishers are manufactured and used.
The following paras deal briefly these extinguishers.
Fire Fighting
When all the above measures fail and a file occurs, to minimise its
effect there should be an efficient the fighting system consisting of
fixed system like the hydrants portable extinguishers and trained
personnel to man these facilities
Since all the sites do not have fixed the fighting system, portable
extinguishers are highly relied up on.
Portable Fire Extinguishers
Equipment used to extinguish and control fires is of two types;

fixed and portable. Fixed systems include water equipment, such
as automatic sprinklers, hydrants and standpipe hoses, and special
pipe systems for dry chemicals, CO2 Halon, and foam. Special pipe
systems for are used in areas of high fire potential where tanks for
storage of flammable liquids and electrical equipment are located.
Fire Prevention 9
Fixed systems however, must be supplemented by portable fire

extinguishers. These often can preclude the action of sprinkler
systems. Not only can they prevent a small fire from spreading, but
they can also rapidly extinguish a fire in its early stages.
Principles of Use
Even though a plant is equipped with automatic sprinklers or other

means of fire protection, have portable fire extinguishers available
and ready for an emergency. The term portable is applied to
manual equipment used on small, beginning fires, or between the
discovery of a fire and the functioning of automatic equipment or
the arrival of professional fire fighters.
To be effective, portable extinguishers must be:
• Approved by a recognized testing laboratory

• The right type for each class of fire that may occur in the
area.
• In sufficient quantity and size to protect against the expected
exposure in the area.
• Located where they are easy to reach for immediate use.
• Maintained in operating condition, inspected frequently,
checked against tampering and recharged as required.
• Operable by area personnel who can find them and who are
trained to use them effectively and promptly.
Classification of fire extinguishers
Portable extinguishers are classified to indicate their ability to

handle specific classes and sizes of fires. This classification is
necessary because new and improved extinguishing agents and
devices are constantly being developed and because larger
portable extinguishers are available. Labels on extinguishers
indicate the class and relative size of fire that they can be expected
to handle.
Use the following paragraphs as a guide to the selection of portable

fire extinguishers for given exposures.
Fire Prevention 10
• Use Class A extinguishers for ordinary combustibles, such as

wood, paper, some plastics and textiles, where a quenching-
cooling effect is required.
• Use Class B extinguishers for flammable liquid ad gas fires,

such as oil, gasoline, paint and grease where oxygen
exclusion or a flame-interrupting effect is essential.
• Use C Class extinguishers for fire involving electrical wiring

and equipment where the dielectric non-conductivity of the
extinguishing agent is of first importance. These units are
not classified by a numeral because Class C fires are
essentially either Class A or Class B, but also involve
energized electrical wiring and equipment. Therefore, choose
the coverage of the extinguisher for the burning fuel.
• Use Class D extinguishers for fires in combustible metals,

such as magnesium, potassium, powdered aluminum, zinc,
sodium, titanium, zirconium and lithum. Persons working in
areas where Class D fire hazards exist must be aware of the
dangers in using Class A, B, or C extinguishers on a Class D
fire. Of course they should also know the correct way to
extinguish Class D fires. These units are not classified by a
numerical system and are intended for special hazard
protection only.
The recommendations that follow are given in NFPA 10 as a guide

for marking extinguishers and or extinguisher locations. They
indicate which extinguisher should be used for a particular class of
fire. Extinguishers suitable for more than one class of fire may be
identified by multiple symbols. Apply markings by decals, painting
or similar methods having at least equivalent legibility and
durability.
1 Extinguishers suitable for Class A fires should be identified by

a triangle containing the letter “A”. If colored, the triangle
should be colored green.
Fire Prevention 11
2 Extinguishers suitable for Class B fires should be identified by

a square containing the letter “B”. If colored the square
should be colored red.
3 Extinguishers suitable for Class C fires should be identified by
a circle containing the letter “C”. If colored, the circle should
be colored blue.
4 Extinguishers suitable for fires involving metal should be
identified by a five-point star containing the letter “D”. If
colored, the star should be colored yellow.
Apply markings to the extinguisher on the front, of a size and form

to be easily read at a distance of 3-ft. (0.9 m).
Location of extinguishers
Locate extinguishers close to the likely hazards, but not so close

that they would be damaged or cut off by the fire. Locate them
along the normal path of exit from the building, preferably at the
exits. Where highly combustible material is stored in small rooms
or enclosed spaces, locate the extinguishers outside the door,
rather than inside. This requires potential users to exit the room
and then make a conscious decision to reenter the room and fight
the fire.
Make the location of extinguishers as conspicuous as possible. For

example, if one is hung on a large column or post, paint a
distinguishing red band around the post. Also post large signs to
direct attention to extinguishers. Keep the extinguishers clean. Do
not paint them in any way that will camouflage them or obscure
their labels and markings.
If an extinguisher is not already plainly marked to indicate the

classifications of fire or types of material for which it is intended,
place signs or cards indicating this information on the wall close to
where it hangs. Marketing indicating special uses can also be
stenciled on the extinguisher or on an adjacent wall. Special labels
are available from manufacturers of extinguishers.
Fire extinguishers must not be blocked or hidden by stock, finished

material, or machines. Then they will neither be damaged by
Fire Prevention 12
trucks, cranes and other operations or corroded by chemical

processed, nor will they obstruct aisles or injure passersby. If
installed out of doors, protect the extinguishers from the elements.
Make plant and warehouse aisles wide enough (1) so that mobile
fire protection unit can be brought close to a fire and (2) so that
aisle can be kept free of obstructions. Mark floor spaces to allow
access to fire extinguishing equipment, and protect extinguishers
with bumpers or guardrails.
Extinguishers weighing over 40 lb. (18KG) should not be more than

3-ft. (1 M) above the floor. Maintain a clearance of at least 4-in.
(10 cm) between the bottom of the extinguisher and the floor.
Distribution of extinguishers
The relative hazard of the occupancy, the nature of any anticipated

fires, protection for special hazards, and requirements of local
codes determine the minimum number and type of portable
extinguisher to be installed for each floor or area. Follow the BIS
requirements.
Selection of Extinguishers
Operating characteristics that make one type of portable fire

extinguisher suitable for certain fire hazards may make the same
type dangerous for others. Secure on-the-job advice from fire
inspection bureaus, fire insurance carriers and fire protection
engineers when selecting extinguishers.
Do not let the extinguisher’s cost be the overriding factor in the

selection process. Remember that good extinguishers are worth
their cost because of the protection they give. Obviously, only
purchase extinguishers listed and tested according to BIS.
Also consider the extinguisher’s design and operating features,

ease of maintenance, and the availability of repair service. If
possible, actually operate and test the extinguisher before making
the final selection. Annexure – 1 give overviews of common types
of extinguishers and their operating characteristics.
Fire Prevention 13
Although extinguishers must be installed in conformance with BIS,

there is some flexibility that can be used to the purchaser’s
advantage. For example, if a certain condition calls for Class B
extinguishers, the required units could be obtained by using
various size dry-chemical and CO2.
Fire Prevention 14
Annexure – 1
Operating Procedure of Extinguishers
Type – A Water stored pressure or Soda Acid type:
Remove safety catch strike the plunger against hard surface which
process either the glass bulb in case of soda acid extinguisher or
carbon dioxide cartridge.
• Shake well in case of soda acid type.

• Invert or hold upright the extinguisher as per instructions.
• Direct the jet of water at the seal of fuel. Slowly covering the
entire burning surface.
Type – B Foam Extinguishers:
• Lift the knob and rotate it to fix in position

• Lift the container and shake it to mix the solutions in the inner
and outer container.
• Reserve keep upright the extinguisher as given in instruction
• Direct the jet of foam on the opposite wall of the container
having burning liquid. Until the foam covers the whole burning
surface.
Type – C Carbon Di-oxide Extinguishers:
• Hold in up right position, pull oout the locking pin.

• Press the operating lever.
• Hold the discharge horn at the modern handle and direct the
gas in a sweeping motion over the fire.
Type – D Dry Chemical Powder Extinguishers:
• Remove the locking pin

• Press the operating lever and direct he powder over the pin.
Fire Prevention 15
Annexure –2
Effectiveness of Fire Extinguishers
Type of Extinguishers
Class of Fire Water Foam Water Jet Vaporizing CO2 Dry

from Hose Liquid Powder
Ordinary fire Yes Yes Yes No No No

(Wood, Rag
etc.)
Flammable No Yes No Yes Yes Yes

Liquid
Electrical No No No Yes Yes Yes

Equipment
Fire Prevention 16
18. On Site Emergency Plan
Introduction
Definition:
A major emergency in a works is one, which has the Potential to

cause serious injury or loss of life. It may cause extensive damage
to property and serious disruption both inside and outside the
works. It would normally require the assistance of outside
emergency services to handle it effectively. Although the
emergency may be caused by a number of different factors, e.g.
plant failure, human error, and earthquake, Vehicle crash or
sabotage. It will normally manifest itself in three basic forms: fire,
explosion or toxic release.
Scope:
Much of the earlier part of this manual has been concerned with
preventing accidents through supervision. Achieving this will reduce
the risk of an accident, but it will not eliminate it altogether.
Complete safety is not achievable, and an essential part of major
hazard control is concerned with minimising the effect of a major
accident.
An important element of mitigation is emergency planning, i.e.
recognising that accidents are possible, assessing the consequence
of such accidents and deciding on the emergency procedures both
on site and off site, that would need to be implemented in the
event of an emergency.
Emergency planning is just one aspect of safety and cannot be
considered in isolation. In particular it is not a substitution for
maintaining good standard inside thee works. Before starting to
prepare the plan, works management should ensure that the
necessary standards, appropriate to the safety legislation, are in
place.
Emergency plans are likely to be separate for on site and off site
matters, but they must be concurrent with each other, i.e. they
must be addressed to he same assessed emergency factors. While
on site plan will always be the responsibility of the works
On Site Emergency Plan 1

management, different situations may place the responsibility of

the off site plan elsewhere.
Objectives:
The overall objectives of an emergency plan are:

a) To localise the emergency and if possible, eliminate it and
b) To minimise the effects of the accident on people and property.
Elimination will require prompt action by operators and works

emergency staff using for example fire fighting equipment,
emergency shut off valves and water sprays.
Minimising the effects may include rescue, first aid, evacuation,
rehabitisation and giving information promptly to people living
nearby.
Identification and assessment of hazards:
This stage is crucial to both on site and off-site emergency planning

and requires works management systematically to identify what
emergencies could arise in their plants. These should range from
small events, which can be dealt with by works personnel without
outside help to the largest event for which it is practical to have a
plan. Experience has shown that for every occasion that the full
potential of an accident is realised there are many occasions when
some lesser event occurs or when a developing incident is made
safe before reaching cull potential.
The assessment of possible incident should produce a report

indicating-
a) The worst events considered;
b) The route to those worst events;
c) The time-scale to lesser events along the way;
d) The size of lesser events if their development is halted;
e) The relative likelihood of events;
f) The consequences of each event.
This report may be part of the hazard assessment report or may be

a separate exercise produced specifically for the purpose of
emergency planning.

Incident should be assessed in terms of the quantity of hazardous

materials, which could be released, the rate of release and the
effects of that release – e.g. as thermal radiation from a fire or
fireball or as a toxic gas cloud – as a function of distance from the
plant.
On-site emergency planning:
1. Formulation of the plan and of emergency services:
The assessment of the risks and hazards in a major hazard works

leads either to improvements being made to the plant, in the form.
The on-site emergency plan must be related to the final

assessment and it is the responsibility of the works management to
formulate it. The plan must therefore be specific to the site. On
very simple sites, the emergency plan may consist merely of
putting key personnel on stand-by and calling in the emergency
services. On large multi-process sites, the plan may well be a
substantial document including the following elements:
a) Assessment of the size and nature of the events foreseen and

the probability of their occurrence.
b) Formulation of the plan and liaison with outside, including the
emergency services;
c) Procedures:
(i) raising the alarm
(ii) communications both within and outside the works;
d) Appointment of key personnel and their duties and
responsibilities:
(i) works incident controller;
(ii) works main controller;
(e) emergency control centre
(f) action on site;
(g) Action off site.
The plan should set out the way in which designated people at the
site of the incident can initiate supplementary action both inside
and outside the works at an appropriate time. An essential element

of the plan must be the provision for attempting to make safe the
affected unit for example by shutting it down. On a complex site,
the plan should contain the full sequence of key personnel to be
called in from other sections or from off site.
2. Alarm and communication mechanism:
Communication is a crucial factor in handling an emergency. It is

the practice at many works that any employee can raise an
emergency alarm, so allowing the earliest possible action to be
taken to control the situation.
Alarm systems vary and will depend on the size of the works. These
should be an adequate number of points form which the alarm can
be raised either directly, by activating an audible warning, or
indirectly, via a signal or message to a permanently manned
location. The alarm should alert the incident controller (subsection
18.2.3.), who should possess the situation and implement
appropriate emergency procedures. In area where there is a high
level of noise, it may be necessary to install more than one audible
alarm transmitter or flashing lights. Automatic alarms may be
appropriate on some sites.
There should be a reliable system for informing the emergency

services as soon as the alarm is raised on site. The details of the
communication arrangements should be agreed locally; in some
cases it may be advisable to have a direct line to the fire brigade.
Predetermined code words to indicate the scale and type of the
emergency may be valuable.
3. Appointment of personnel and definition of duties:
Effective emergency plans require that, in the event of an accident,

nominated individuals are given specific responsibilities, often
separate from their day to day activities. The following are the key
personnel and their duties.

Organisation and Responsibilities
Site controller (RCM/RE)
On getting information from any authentic source, he proceeds

promptly to the emergency center and takes overall charge of the
activities for dealing with emergency.
a) He remains in the emergency control center till the emergency

is called of so that all concerned are aware of the location of his
availability during the emergency.
b) He communicates and co-ordinates among various team
leaders.
c) He is the final authority on all matters related with management
of emergency such as fire fighting, rescue operations, calling
outside agencies for assistance, evacuation, transport, liaison,
public relations etc.
d) He will perform all duties required to be done regarding
mechanical, electrical and other assistance as required during
the emergency.
e) He will undertake all rescue operations.
f) He will maintain liaison with all government agencies regarding
the emergency.
g) He will take all steps required for welfare such as providing tea,
snacks in the canteen.
h) He will also be responsible for the head count at the assembly
point.
Responsibilities of unit in-charge (Engineer at site)
a) Report to the site controller and site co-ordinator about the

emergency.
b) He will regulate the entry and exit of personnel required for
controlling the fire/emergency.
c) He will arrange PPE required for emergency.
d) He will call the local fire brigade, police in case of necessity in
consultation with the site controller/site co-ordinator.
e) He will be responsible for providing transport facilities for
evacuation of personnel to medical center (Hospital) or to a
safer place.

f) He will collect and disseminate information as required to all

concerned.
g) He will keep detailed report of the incident and the progress
of operations to fight emergency.
h) In case of power failure/telephone service disruption, he will
arrange for messenger for the purpose of communication.
i) He will work in consultation with the site controller.
Site co-ordinator (SSO)
a) He will co-ordinate the activities of all the team.

b) He will evaluate the safety and health hazards.
c) He will co-ordinate the transport services, arrange for
temporary shelter in consultation with the Unit-Incharge.
Rescue / Evacuation team (Member of Safety Committee)
a) This team will directly fight the emergency under the

instructions from Unit-Incharge / Site co-ordinator.
b) The team leader will be the erection / Construction supervisor
or engineer and will be assisted by various engineers for
controlling the emergencies.
c) He will ensure that the emergency does not escalate but is
controlled the extinguished with the spot of occurrence.
d) He will ensure that he and his team members wear the
necessary Personal Protective Equipment while searching for
the missing personnel.
e) The leader will mobilize his team and establish contact with
the Site Contractor regarding manpower accounting and start
the searching operation if required.
f) The trained person in fire fighting will restrict the movement
of person to effectively cordon off the emergency area and
start fighting with fire / explosion.
g) Rescue team should send out all tankers, lorries and
flammable material to a safer place.
h) Trained person in first aid will give assistance to injured
persons.
Apart from these personnel other works personnel will have key
roles to play in the implementation of the emergency plan. These

will include senior managers of plants not directly involved in the

emergency, first aiders, atmospheric monitoring staff, casualty
reception staff and public relations staff to liaise with the media. All
need to be aware at the emergency pre-planning stage of the
precise nature of their roles.
Emergency control centers
The emergency control center is the place from which the

operations to handle the emergency are directed and co-ordinated.
It will be attended by the site main controller, key personnel and
the senior officers of the fire and police services.
For a small works it may be a designated office which converts to a
control centre in the event of an emergency. For large works, a
purpose-built family is advisable. In all cases, however, the centre
should be equipped to receive and transmit information and
directions from and to the incident controller and other areas of the
works, as well as outside.
Emergency control centres should therefore control the following

(as applicable):
1. An adequate number of external telephones; if possible, one
should accept outgoing calls only, in order to bypass jammed
switchboards during an emergency;
2. An adequate number of internal telephone;
3. Radio equipment;
4. A plan of the works, to show:
(i) areas where there are large inventories of hazardous
materials;
(ii) sources of safety equipment;
(iii) the fire fighting system and additional sources of water;
(iv) site entrances and roadways, including up-to-date
information on roadworks;
(v) assembly points;
(vi) the location of the works in relation to the surrounding
community;
(vii) lorry parks and rail sidings; (additional works plans
should be available to show affected areas, etc., during
an emergency;)
5. notepads, pens and pencils;

6. a nominal roll of employees;

7. a list of key personnel, with addresses, telephone numbers,
etc.
The emergency control center should be sited in an area of

minimum risk. For large sites, or where toxic releases might be
anticipated, consideration should be given to setting up two control
centers to ensure, as far as possible, that one will always be
available for use should the other be put out of action.
Action on site
The primary purpose of the onsite emergency plan is to control and

contain the incident and so to prevent it from spreading to nearby
plant. It is not possible to cover every eventuality in the plan and
the successful handling of the emergency will depend on
appropriate actions and decisions being taken on the spot. Other
important aspects needing to be considered include the following:
• Evacuation of non-essential persons from the site.
• Accounting for all personnel listed as present in the premises.
• Access to records for informing next kith and kin of injured
persons.
• Rehabilitation of the work site to the normal condition.

Planning shut-down procedures
For single plant sites, shutdown procedures may be comparatively

simple, with no knock-on effects elsewhere on site. With complex
sites, such as large petrochemical works or refineries, plant
operations are often interlinked and the shutdown of any key plant
on site (e.g. a power station) may have significant implications for
other plant. Emergency plans will need to take account of this so
that ordered and phased shut-downs can take place when
necessary, depending on the type of incident occurring.
Rehearsing emergency procedures
Once the emergency plan is finalised, it should be made known to

all personnel so that each knows his or her role in the event of an
emergency. It is essential that the plan is regularly tested because
it is only through such rehearsals that defects become apparent.
The plan can be tested in a number of different ways.
Communication is a key component of handling an emergency and
a rehearsal of the communications system, including contingency
action if part of the system (e.g. telephones) becomes inoperative,
should be undertaken. Evacuation rehearsals should be regularly
carried out and should cause minimum disruption to the normal
activities. More elaborate exercises, involving the emergency
services where they are part of the emergency plan, will also need
to take place. The procedure for mock drill is given in annexure-1.
Many organisations use table-top exercises test their emergency
plans. These are very cost effective because they do not interrupt
the day-to-day running of the plant and because the organiser of
the exercise can “arrange” for a variety of difficulties to arise which
will need on-the-spot decisions to be taken. Full-scale exercises,
providing a realistic rehearsal setting, will still be needed to
complement the tabletop exercises. DOs and DON’Ts are given in
annexure-2.
Plan appraisal and updating
Emergency planning rehearsals and exercises should be monitored

by observer not involved in the exercise, and preferably
independent of the site, e.g. senior officers from the emergency
services or factory inspectorate. After each exercise, the plan

should be thoroughly reviewed to take account of omissions or

shortcomings. Emergency plans, particularly for complex sites, are
the subject of continual refinement and updating out it is very
important that any changes of substance are made known to those
likely to be involved in that part of the plan when used for a real
emergency.

Annexure-1
Do’s and Dont’s
Do’s
1. Give attention to all instructions.

2. Report to your Team Leader and carry out your assignment.
3. Conduct the visitors / contract labourers outside the emergency
zone to designated location.
4. Only qualified First Aiders shall render First Aid wherever possible
and await for the Doctor.
Dont’s
1. Do not panic.
2. Do not communicate with any external unless instructed by the
Site Controller.
3. Do not spread unauthorized or exaggerated information to others.
4. Do not approach the emergency site as a spectator.
5. Do not engage unnecessary the communications aids like
telephone / Public Address Systems (PAS) and other means to
make the same available for handling emergency.
6. Do not disturb the leader assigned with specific work for handling
emergency.

Annexure-2
Procedure for mock drill
a) Inform all the employees about MD and signal to all.

b) Fix date and location of emergency for MD.
c) MD shall be monitored by an observer who is not involved in the
exercise.
d) Raise the siren for emergency.
e) Site Controller, Unit-Incharge, Co-ordinator and Team Leaders shall
follow their stipulated duties/responsibilities.
f) Some persons should cordon off the emergency area.
g) All clear signal should be raised after half an hour.
OEP Appraisal and updating
Mock Drill will be monitored. After each drill the plan will be thoroughly
reviewed to take account of omission or shortcomings and updated
response time for each action will be noted and studied for any
improvement.
Procedure on noticing an emergency
A) Inform the nearest Unit-Incharge.

B) Get back to your normal work station if safe, or else report to the
Emergency Control Centre.

Environment Protection
In the construction site adequate measures are taken not only to fulfill all
the statutory requirements but also to conform to the norms laid down in
ISO 14001 for certification.
It is necessary to incorporate an environmental management system at

the planning stage itself so that along with the progress of site
development the attendant environmental problems are also attended to.
The environmental management system provides a structured process for

the achievement of continual development/improvement at the site; the
size and other parameters of the site will decide the rate and extent of
which.
The system consists of:

• A Corporate Policy has been established which includes the
Environment Policy
• Establishing the requirements at the site as per the Central/ State
legislation.
• Identifying priorities for setting appropriate objectives and targets
• Establishing a structured programme to gradually implement the
requirements as and when the need arises.
And
• Establishing control/monitoring/corrective procedures to maintain the
facilities at the required level.
The process to identify the significant environmental aspects associated

with the activities at the site should, where relevant, consider,
• Emissions to air
• Releases to water
• Waste management
• Contamination of land
• Use of raw materials and natural resources
• Other local and community issues
The last two issues, namely, use of raw materials and natural resources
and local and community issues will have to be dealt by the client and
Environmental Protection 1
the local authorities. The E & C ‘s role in these to identify areas and
suggest remedial measures to the client for consideration and
implementation. The action to be taken at the site on the other 4 issues
is briefly described in the following paras.
The three remaining aspects namely air, water and soil pollution are to
be considered and incorporated in the system so that, at any given time,
the pollutants under the above 3 categories do not exceed the statutory
limits.
AIR POLLUTION:
At the site, blasting, excavation, piling and concreting operations are the
essential activities undertaken and these provide air pollutant in the form
of dust.
Adequate precautions are taken to control the concentration of the

pollutants within the prescribed limits.
During blasting the explosives are placed in such a manner that the
debris fall within the site limits. In the site itself, the blasting area is
cordoned of so that the falling debris does not harm the workers.
Piling, excavation and concreting are done in wet conditions thereby

minimizing the emanation of the dust.
As regards using the Diesel Generator sets, it is ensured for the proper
performance of the set so as to keep the pollutants, Sulfur di oxide and
Carbon monoxide level below the prescribed levels.
WATER POLLUTION:
At the site, the water pollution can occur due to following reasons:
The wastewater from washing facility, toilets are adequately handled.

If the site is in an existing factory then it is let in to the factory drains.
The wastewater from the washing facility is drained through a soak pit.
Since all these work are done through contractors, the solid waste
from the canteen is collected and disposed off.
A major hazardous pollutant at the site is the wastewater collected

from the acid and alkali washing of vessels and nuetralised. The
wastewater after removal of the sediments is let out to the common
drain/soak pit.
SOIL POLLUTION:
From the above measures most of the pollutants are prevented from
getting absorbed by the soil. However the earth removed due to
activities like excavation etc; are used for levelling the ground for
making garden / planting of trees.
The organisation thus makes a conscientious effort to ensure fulfilling

all the statutory requirements to maintain a proper environment at the
work site handling, storage and transportation of hazardous materials
are dealt at the appropriate chapters.

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Larsen & Toubro Limited

Safety Health & Environment Manual

SAFETY, HEALTH AND ENVIRONMENT

Part I: SHE - Administration

3.4.1. Basic Requirements for Contractors

Part II: SHE - Implementation

4. Concept of Accident Prevention

11 Occupational Health Center and First Aid

Part III: Commissioning of plant

Part IV: Environment protection

On behalf of Safety Control Department I am pleased to issue this

This four-section manual contains information based on the most

I appreciate the assistance given by D.Venugopal our consultant, all

I hope, By following safe methods and procedures in construction let

1.1.1 This Safety, Health and Environment Management Manual has

1.1.2 This Safety, Health and Environment Management Manual

1.1.3 This Safety, Health and Environment Management Manual shall

5. To continually reduce the risk of pollution through setting environmental objectives in

6. To deploy Information Technology for increasing the efficiencies of our business

8. To encourage enthusiasm, innovation and empowerment whilst developing inspiring

3. SHE organisation and Management

In order to implement the policy of the management given under

3.1. Management Commitment

The E&C Division of L&T, is committed to continuous

SHE Organisation & Management 1

Pursuant to the L&T Safety Policy Statement, we L&T employees at this

SAFETY FIRST Site Safety Officer ________________

Resident Construction Engineer ________________

11th January, 99. Resident Construction Manager ________________

3.2. SHE Structure

The SHE organisational structure of L&T’s E & C Division Safety

Sr.Vice President (Operation)

Safety Site Safety

SHE Organisation & Management 3

3.2.1. Safety Control Organisation Structure

3.2.2. Site SHE Organisation Structure

The Site SHE organisational structure of L&T’s E & C Division

3.2.3 Duties and Responsibilities

3.2.3.1.1 The management shall have ultimate responsibility for SHE

SHE Organisation & Management 4

3.2.3.2. Safety Control Department Responsibilities

3.2.3.2.1. To set up standards for prevention and control of losses

3.2.3.3. Resident Construction Manager

He is overall in-charge of the safety of the site, for the

3.2.3.3.1. To ensure & maintain safe working conditions and practices

SHE Organisation & Management 5

3.2.3.3.7. To encourage safety suggestions and act upon them

3.2.3.4. Site Engineer

The site engineer is responsible for ensuring the compliance

3.2.3.4.1. Inspect working area regularly.

3.2.3.5. Site Safety Officer

The site safety officer is responsible to ensure the over all

3.2.3.5.1. Promote & implement the SHE manual at project sites.

SHE Organisation & Management 6

3.2.3.5.5. Advise RCM to stop work when the need arises.

SHE Organisation & Management 7

3.2.4.1. Reporting about Opening/ Closing of Construction Sites

In order to conform with norms set in the safety policy, it is

A detailed procedure is given below for compliance.

3.2.4.1.2.1 This Procedure requires that SCD at Powai should be

3.2.4.1.3.1. Opening of a Construction Site

3.2.4.1.3.1.1. An event/day when L&T personnel or L&T’s contractor/s or

3.2.4.1.3.2. Closing of Construction Site

Date: Signature: ______________________

Date: Signature : ___________