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OHSAS 18001

What is OHSAS 18001 ? Created by concerted efforts of a number of the worlds leading national standards bodies, certification bodies, and specialist consultancies to remove confusion in the workplace by the introduction of a certifiable OH&S specification

Specification gives requirements for an occupational health and safety management system, to enable an organisation to control its OH&S risks and improve its performance.
Developed to be compatible with both the ISO 9001 and ISO 14001 management systems standards

OHSAS 18001 as Part of IMS


Integrated Management System
ISO 9001: 2000 ISO 14001: 2004 OHSAS 18001:1999 Quality Environment Safety & Health

OHSAS 18001
Similar to ISO 14001 Followed by a consortium of countries Indian Standard IS 18001

Road to OHSAS 18001 Certification An OHSAS 18001 certificate means that the system has been measured measured against a best practice standard and found compliant. Issued by a third party accreditation body / registrar. Certificate lets employees and other stakeholders know that the Company proactively protects the health and safety of your work force. Steps to be followed ? Obtain a standard (Done) Review literature and software (Done) Assemble a team and define your strategy (Done) Determine training needs(Done) Review consultant options (Done) Develop a management systems manual (Ongoing) Implement management system (Ongoing) Consider a pre-assessment (Being Done)

PDCA Cycle
OHSAS 18001
Policy Planning (Plan) Implementation (Do) Checking (Check) Management Review (Act)

Initial Status Review

Continual Improvement

4.2 OH&S Policy 4.3 Planning PLAN


4.3.1 Planning for hazard identification, risk assessment and risk control 4.3.2 Legal & other requirements 4.3.3 Objectives 4.3.4 OH&S management programme(s)

4.6 Management Review ACT

4.5 Checking and CHECK Corrective Action


4.5.1 Performance measurement and monitoring 4.5.2 Accidents, incidents, non-conformances and corrective and preventive action 4.5.3 Records and records management 4.5.4 Audit

4.4 Implementation & DO Operation


4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 Structure & responsibility Training, awareness & competence Consultation and Communication Documentation Document and data control Operational control Emergency preparedness & response

IMS Policy
ITD Cementation India Limited (ITD Cem), an ITD Group Company, is one of the leading construction companies in India.

Concern for Quality, Environment, Occupational Safety and Health drives ITD Cem to conduct its operations in a responsible manner

We, at ITD Cementation India Limited, shall strive to: Meet clients requirements for quality of works and project completion time; Comply with applicable environmental, occupational safety and health related legislations; Prevent and control pollution, minimise consumption of resources and generation of waste through adoption of better practices and technology; Provide safe and healthy work environment through through adoption of better practices and technology Carry out audits on regular basis to ensure that systems are in place, updated and continually improvement; and

Improve awareness, through campaigns and training programs among employees, contractors and clients, about significant environmental aspects, occupational safety and health risks and control measures It would be our endeavour to make ITD Cem a strong and pro active organisation providing quality product in an eco friendly, healthy and safe environment

OHSAS 18001 PDCA Thinking

Act Plan
Decide what action is needed, e.g. adopt the change permanently; abandon the change; make some adjustments and go round the cycle again

OH&S policy

Act

Plan who will do the work and when? What equipment or training do they need? How will information for assessing success be collected and recorded? When will progress be reviewed?

Plan DO

Check Do
Check the information gathered. Was the desired outcome achieved? If not what actually happened

Check

Do the work according to the plan

Towards Continual Improvement

PLAN

OHSAS 18001 PDCA Thinking

Act Plan

OH&S policy

Act

4.3.1 Planning for hazard identification, risk assessment and risk control 4.3.2 Legal and other requirements 4.3.4. OH&S management 4.3.3 Objectives program

Plan DO

Check Do

Check

Towards Continual Improvement

HAZARD IDENTIFICATION &


RISK ASSESSMENT

Occupational Safety & Health Risks today


Chemicals Safety Organization

Physical

Ergonomics

Psychosocial

Dust, noise,light, temperature

Tools Workingpositions Heavy work

Globalization 24-hour man

Losses in Construction Industry


Loss to: P E M E People Equipment Material Environment

CHOICE

Injury Free Workplace

VALUE

COMPLIANCE Construction Site PRIORITY

We should involve the entire company, subcontractors, and clients to change safety from a PRIORITY to a VALUE and from COMPLIANCE to a CHOICE.

RISK ASSESSMENT
Hazard Something with the potential to cause harm The likelihood of harm being caused The number of persons who might be affected and the consequences

Risk

Extent of Risk-

Definitions ? Accident: undesired event giving rise to death, ill health, injury, damage or other loss Critical Task: task which has the potential to produce major loss to people, property, process, and / or environment when not performed properly. Hazard: source or situation with a potential for harm in terms of human injury or ill health, damage to property, damage to workplace environment, or a combination of these. Improvement Programme: achieving its objectives. Management program for

Incident: Event that gave rise to an accident or had the potential to lead to an accident.

Risk Assessment & Review


SAFE SITE

REVIEW PERFORMANCE DEFINE& COMMUNICATE DUTIES/ RESPONSIBILITIES SPECIFY PREVENTIVE OR PROTECTIVE CONTROL MEASURES ASSESS/ EVALUATE RISKS IDENTIFY HAZARDS DEFINE OPERATIONS ACTIVITIES, PROCESSES

DEVELOP METHOD STATEMENT

RISK ASSESSMENT
PREVENTATIVE AND PROTECTIVE MEASURES
Terminate
ELIMINATE HAZARDS

Treat
COMBAT RISK AT SOURCE

Tolerate
DEVELOPE SAFE SYSTEM OF WORK

Transfer

USE PPE

Risk Assessment 4.3.1


Risk Assessment Process
Listing out activities Identifying hazard Evaluating risk Deciding and Implementing control measures Monitoring and reviewing assessment People Equipment Procedure Work place Materials Arrange hazards in order of priority

Identify Hazards

Evaluation of risk
Risk rating score (RRS)
Risk essentially a combination of three factors
Number of people that could be affected Severity of likely injuries that persons could suffer Likelihood of harm actually occurring

Risk Rating = Number*Severity* likelihood

Risk Rating Score


No of people/ Exposure (N) 1-5 / 1 Occasional Exposure(yearly) 6-50/ Seldom 2 1 Exposure (Monthly/Weekly) 50+/ Public/ 5 Vulnerable Person/ Continuous/daily 3 Severity (S) Negligible < Rs 10,000/ Likelihood 1 (L) Improbable 0.5

Minor Rs 10,000 2,00,000/ Major Rs 2,00,000/ 5,00,000/

Remote

Possible

Likely

10

Negligible Injuries. Cuts, abrasions,bumps Minor injuries. Injuries in time off work Major Injuries. Broken limbs, injuries to eyes, asphyxiation (In our case any injury with absence greater than 48 hours) Improbable. Possibility close to zero Remote. Unlikely Possible. Could occur sometimes Likely. No surprise that it will happen

Risk Rating Score < 10 risk acceptable unless cost or effort to control further is low 10 19 Risk is low. Action required to reduce risk, although low priority.Time effort and cost to be proportional to risk 20 49 Risk is medium. Action required soon to control hazards. Interim measures required to control risk 50 99 High risk. Urgent action required to control risk. Interim measures required in short term > 100 Unacceptable risk. Immediate action required to bring RRS below 100 before work can actually commence

Risk assessment should be reviewed at regular intervals to ensure that risk is properly controlled If the score is low due to effective measures in place, action must be taken to ensure that measures remain in place Example. A worker is using a metal casing electric drill in damp conditions. No checks made on the drill. The drill is old

Example. A worker is using a metal casing electric drill in damp conditions. No checks made on the drill. The drill is old
Risk Rating = 1* 10* 5 = 50
(1-5)*(Fatal)*(Possible)= High Risk

Control measures to prevent accidents. Check earth wires. Move operations to dry area. Planned maintenance of power tools Residual Risk Rating = 1*10*1 = 10
(1-5)*(Fatal)*(Remote) = Low Risk

Example 2
A worker is trying to tie up reinforcement rods standing on top of a temporary platform at a height of 9m built over a pipe scaffold over an uneven ground. There are no base plates and a water drain flows near the base of the scaffold.

Risk Rating Score 2*5*10 = 100


(1-5)*(Major)*(Likely) = High Risk

Remedial Measures Level The ground. Provide firm base with steel plates Provide a barricade around platform Increase width of platform to at least 60 cm Personnel to use safety belt from an independent anchor point Residual RRS 1*5*1 = 5
(1-5)*(Major)*(Remote) = Acceptable

Risk Assessment Form


R-1/22

SKANSKA CEMENTATION INDIA LIMITED


RISK ASSESSMENT FORM
Site: ___________________________ Activity ___________________________________________ ___________________________________________ Assessment Date: __________________

SR NO

TASK

ROUTINE / NON ROUTINE

HAZARD

HAZARD EFFECT

RISK RATING SCORE N S L RRS

CONTROL MEASURES

OCP / IP

RESIDUAL RISK RATING SCORE N S L RRS

CRITICAL TASK

Name of Assessor(s) ____________________ ____________________

Review on___________________________ _________________

Review by ______________________

Critical Task: Task which has the potential to produce major loss to people, property, process, and / or environment when not performed properly.

Based on statistics of injuries and experience at site, activities pertaining to following trades have been analysed for identifying critical tasks: (a) Vehicle/tractor/trailer driver (b) Crane operator (c) Electrician (d) Pump/ Winch operator (e) Driller (f) Unskilled worker

Factors of task criticality


Severity potential Frequency of exposure Probability of loss

Severity criteria (s) 0 No injury, illness, property damage, or other loss of


2 4 less than Rs 10,000. Minor injury/illness without lost time, non-disruptive property damage, or other loss of Rs 10,001 to Rs. 2,00,000. Loss time injury/ illness without permanent disability, or disruptive property damage, or other loss of Rs. 2,00,001 to Rs 5,00,000. Permanent disability or loss of life or body part, and/or extensive loss of structure, equipment, or material, or other loss exceeding Rs 5,00,000.

FREQUENCY CRITERIA (F) Number of Persons Performing Task Number of Times Task is Performed by each Person Few Times per Day 1 Many Times per Day 2

Less than Daily

Few( 1 5 )

Moderate Number (6 20)


MANY ( > 21 )

Note: Number have been fixed by the Management for entire organisation

PROBABILITY (P) LIKELIHOOD OF LOSS OCCURRING

-1
0

LOW PROBABILITY OF LOSS


MODERATE PROBABILITY OF LOSS

+1

HIGH PROBABILITY OF LOSS

CRITICALITY = S + F + P This number has been fixed by the organisation. If S+F+C is greater than 6, then the task is a critical task)

Occupation: Crane Operator

Criticality
Major Loss/ Exposure

S.No 1. 2. 3. 4. 5.

Task/Activity Moving crane Lifting load Moving with lifted load Maintenance and repairs Operating RT-3

S 0 4 4 2 4

F 2 2 2 1 2

P -1 0 1 0 -1

C 1 6 7 3 5

Remarks

Crane overturning/ crush injury Failure of sling / Injury to personnel Failure of sling / Injury Minor injury Damage to equipment / Injury to personnel Failure of wire rope due to extra load / Injury to personnel Damage to equipment

CT

6.

Operating grab

4 4

2 2

+1 -1

7 5

CT

7.

Operating vibro

Occupation: Vehicle Driver

S.No 1.

Task/Activity Forward driving and parking Reversing

Major Loss/ Exposure

S 4

F 2

P -1

C 5

Remarks

2.

3.

Maintenance and running repairs

Injury to self or public / vehicle overturning Vehicle running over / crushing others Minor injury

4 2

2 2

+1 -1

7 3

CT

CRITICAL TASK ANALYSIS WORKSHEET DEPARTMENT OCCUPATION TASK Mechanical Vehicle Driver Reversing of vehicle Date: Reviewed By: Approved By:

Specific Loss Exposure Improvements/Suggestions No Task Steps Recommended Controls 1 Reversing from a parked position 1a Driver starting to Injury to personnel Driver to check underneath and Helper to guide as per norms reverse by getting sleeping/resting/standing behind before getting into the vehicle into the vehicle behind the vehicle Driver to go around the vehicle 2 Vehicle being reversed in continuous movement Helper to dismount Injury to helper from the vehicle to go to rear of vehicle Start reversing Person/animal run over Vehicle fall over from height or on slope Helper to move to the rear of the vehicle from the front side of the vehicle Reverse horn Helper to give signals Stopper to be provided Driver not to start reversing till helper reaches the spot and signals

2a

2b

Vehicle to be periodically checked Stoppers to be periodically checked

CRITICAL TASK ANALYSIS WORKSHEET DEPARTMENT OCCUPATION TASK Mechanical Electrician Work on live electrical circuit Date: Reviewed By: Approved By:

No 1 2

Task Steps Identify task Working on live circuit Touching the live wire Touching the live wire

Specific Loss Exposure

Improvements/Suggestions

Recommended Controls

Loss of life

Ensure the weather is dry Ensure that the electrician is not wet or is not perspiring

Work on live electric circuit to be permitted only on dry days and during cool hours

Loss of life

Use rubber hand gloves and insulated All electricians to be issued with rubber tools hand gloves and insulated tools Work on only one conductor, ensure the other conductor is visibly seperated

Loss of life

CRITICAL TASK ANALYSIS WORKSHEET DEPARTMENT OCCUPATION TASK Mechanical Crane operator Operating Grab Date: Reviewed By: Approved By:

No Task Steps 1 Positioning of crane 2 3 Lifting the grab Grabing

Specific Loss Exposure Damage to load

Improvements/Suggestions Recommended Controls Crane to be positioned on level and Lift supervisor to check the position firm ground and as near to the load as possible

Injury to personnel

Area to be barricaded and no person Crane helper to check allowed inside Failure of wire rope due to Wire ropes to be periodically Mechanical engineer to regularly inspect excessive load inspected the condition of ropes Excessive pressure not to be applied, Site supervisor to ensure action on incase hard rock/obstruction encountering rock/ obstruction encountered grab to be withdrawn and chiseling to be done

APPLICABILITY OF LAW 4.3.2

Statutory requirements are stated in


Building and other Construction Workers (Regulations of Employment and Conditions of Service) Act, 1996 & Central Rules,1998

Important Statutory Requirements


BOCW Act 1996 & Rules 1998 Constitute a safety committee Appoint a safety officer for strength up to 500 workers Reporting of lost time accidents of time loss more than 48 Hrs A written notice of commencement of work to authorities at least 30 days prior to start of work Duties of employers erecting scaffolds Lifting appliances, gear, devices, transport equipment and other devices to be used if these comply with provisions and are tested and examined. Record of inspection to be maintained Change of ownership to be intimated to registering officer with in 30 days of change Noise levels not to exceed limits Provide fire extinguishing equipment and trained personnel Fire extinguishers in each launch, boat and lifting appliance

BOCW Act.. Prepare emergency plans Dangerous parts of machinery protected and not lubricated Signed written statement of policy to be submitted to Director General and displayed when workers > 50. Confined space like tank, trench or excavation to be certified safe by responsible person Eye protection for workers engaged in welding, cutting, grinding Provide helmets, boots and other apparel Implement measures to prevent persons coming in contact with electrical equipment Vehicles to conform to Motor Vehicle Act 1988 and drivers to hold valid license Chain to be inspected once every month and wire of lifting appliances once in three months. Annealing of rings Vessel for transportation over sea to carry life buoys Electric vibrators earthed

BOCW Act Tunneling work Steep roof work Pressure plants examined by competent person Handling of explosives Piling equipment and operations Medical examination Operator of crane, winch or other lifting appliances Identified workers subjected to hazards and risks Provision of ambulance room Provision of ambulance van Notice of poisoning and occupational disease to authorities Gas Cylinder Rules 1981 Oil and grease not to be used on valves or other fitting Empty cylinders segregated from filled ones Storage of gas cylinders to have flame proof electrical appliances

Gas Cylinders.. Protection of gas cylinders by a stout metal cap Storage license required if LPG > 100 Kg Flammable gas cylinders > 15 or 125 Kg Non flammable and non toxic > 50 DA cylinders > 15 Petroleum Act License not required if If Petroleum cl B does not exceed 2500 ltrs and receptacle size not greater than 1000 ltrs No electric line in storage shed All equipment in storage shall be earthed. Bonding done for pipes

Legal Compliance
Legal Compliance is through procedure P 23
Relevant permissions like quarry sites Mandatory inspections e.g cranes and lifting appliances and compressed vessels Mandatory measurements and monitoring like noise levels PPE provided Records to be maintained

Objectives and Targets (Company) 4.3.3


Objectives & Targets
Reduction in AIR. Reduction of AIR by 5% for 2005 and for subsequent years up to 2010. Training in safety awareness. Half a day workshop for all sites to train 500 engineers / supervisors during 2005. Continual improvement of Management System. One nominated site to be audited by professional agencies like CLI or NSC. Assessment of sub contractors safety performance. Introduction of pre contract and post contract assessment form in respect of 20 major sub contractors Medical Inspection of Operators and drivers. Medical inspection in respect of all crane operators to be carried out.

Site specific objectives & targets


Objective To Provide an Injury Free Environment at B 2824 Project site. Targets 100 % Cranes shall be certified by a competent person before being put to use. Issue of PPE to 100 % staff and workers prior to or immediately after induction Use of PPE by 100 % personnel at site All electrical distribution boxes shall have ELCBs of 30mA cut off rating Walk about by Project In charge on each Tuesday Toolbox talks by engineers twice a week

Improvement Programs 4.3.4


Company
Training of 500 engineers / supervisors External training of 16 engineers from CLI / NSC or other professional agencies External audit

Sites
IP 1 IP IP IP IP 2 3 4 5 Training of vehicle helpers and drivers in reversing vehicles Train workers in manual handling Train Crane operators Train workers in working around plant Train banks man / helper

PLAN DO CHECK ACT

OHSAS 18001 PDCA Thinking

Act Plan

OH&S policy

Act
Check Do

Plan
4.4.1 Structure and responsibility 4.4.2 Training awareness and competence Consultation and communication Documentation Document and data control Operational control Emergency prepareness and repsonse

Check
4.4.3 4.4.4 4.4.5 4.4.6 4.4.7

DO

Towards Continual Improvement

Structure and Responsibility (4.4.1)


Responsibility and authority
Project in charge Front /works in charge Site engineers and supervisors Safety officer Workers Other employees

Training 4.4.2
Induction training Toolbox talks Monthly training In-house training Managers training as identified by corporate HR

Consultation & Communication4.4.3


IMS Policy
Training organised by safety officer Display of policy on board Issuing roles and responsibilities and obtaining signatures in a register Site review meetings

Legal Requirements
Legal register Site safety meeting

Other safety issues, safety alerts etc


Safety meetings Review meetings Display boards Clients meetings, feedback from clients Visitors comments register

Documents and Documents Control 4.4.4 & 4.4.5


Documents to be maintained by sites as per earlier requirement Additional requirements
Law compliance Measurement and monitoring Sub contractors assessment Feed back from clients

Operational Control Procedures 4.4.6

Safety and Health Control Procedure (SHOP) Clear and simply worded procedures which are easily understood by most employees to make our operations smooth, safe and efficient A total of 19 OCPs (SHOP)

Details of SHOP
SHOP 1 SHOP 2 SHOP 3 SHOP 4 SHOP 5 SHOP 6 SHOP 7 SHOP 8 SHOP 9 SHOP 10 SHOP 11 SHOP 12 Issue and Use of PPE Working at Heights Scaffolds and Working Platforms Confined Space Tunneling Working at Night Working Over/near Water Working on Live Roads Electricity Excavations Arc Welding and Flame Cutting Manual Handling SHOP 13 Use of Plant Equipment and Machines SHOP 14 Lifting Appliances and Lifting Gears SHOP 15 Diving Shop 16 Fire Prevention SHOP 17 House Keeping SHOP 18 Accident/Incident Investigation and reporting SHOP 19 Safety and Health Control of Subcontractors

Emergency Preparedness and Response Plan 4.4.7


Identify potential emergencies
Fire Collapse of structure Fall of person in water Evacuation for serious injury or illness Flash floods Natural calamity

Emergency Plan Important telephone numbers

PLAN DO CHECK ACT

OHSAS 18001 PDCA Thinking

Act Plan

OH&S policy

Act
4.5.1 Performance measurement and monitoring

Plan DO
Towards Continual Improvement

Check Do

4.5.2 Accident, incidents, nonconformance and corrective and preventive action 4.5.3 Records and records management 4.5.4 Audit

Check

Performance measurement and monitoring 4.5.1


Key Performance Indicators
No of injuries AIR No of dangerous occurrences No of toolbox talks conducted No of sub contractors trained No of walk abouts taken No of safety inspections by Senior Management No of persons trained in critical tasks Observations raised by Senior Management visiting site

4.5.2 Accidents incidents, non conformances and corrective and preventive measures
Report accidents and incidents Carry out investigations Recommend and implement control measures Record non conformities and take corrective and preventive action

4.5.3 Records and Records Management


Details of records to be maintained given in P - 2

4.5.4 Inspection and Audit


Inspection at site level by safety officer Walk about by Project In charge Internal safety audit by safety managers IMS audit

PLAN DO CHECK ACT

OHSAS 18001 PDCA Thinking

Act Plan
4.6 Management Review

OH&S policy

Act

Plan DO
Towards Continual Improvement

Check Do

Check

4.6 Management Review


Monthly reports BU ORM Management meeting

OHSAS 18001 Is an extension of the existing system and no extra effort is required Is simple, logical and step wise Shall enable sites to perform efficiently Reduce wastage and add to bottom line Raise status of the Company Shall enable Company to qualify for projects of multinationals

What are sites expected to do?


Enunciate site safety policy based on Company Safety Policy. Communicate to everyone by: Displaying it Hindi and local language at appropriate places Making engineers and supervisors sign a register with safety policy pasted in it

Carry out risk assessment and record the same as part of safety plan. This is the heart of the system and should be carried out as Group risk assessment. Be aware of the statutory requirements mentioned in the law register. Comply with these and record compliance. Law register containing environmental and safety requirements shall be provided by the Corporate. Identify critical tasks over and above those identified by the Corporate Set site objectives and targets based on requirements. Decide on improvement programs to achieve targets.

DO Structure and responsibility Structure matrix already available in the IMS Manual Communicate responsibility and authority and communicate the same by making all concerned to sign in a register. Training. Ensure that training is carried as detailed below Induction training Toolbox talks Monthly training on last Saturday of the month Training for critical tasks In house training as planned by the Corporate External training for engineers and supervisors as detailed by Corporate

Consultation and Communication Communication of policy and safety plan Monthly safety meeting and review meeting at site Communication of safety alerts

Legal requirements
Communicate safety issues Feed back from customer Feed back from visitors Pre contract meeting and assessment of contractors Documents and documents control As is being done for quality and environment Make a safety plan of the site as per CD issued to site Submit reports and returns as per formats, additional reports and returns are law compliance, measurement and monitoring, sub contractors assessment

Operational Control Procedures (SHOP)


SHOP 1 19 Simple operational procedures for safe work and to reduce the risk To be known by all concerned, specially about five key identified areas.

Emergency Plans Emergency plans already Written down. Communicate these to all. Display these on boards Conduct mock drills and keep a record Send mock up drill reports to Corporate offices Display important telephone numbers to deal with emergencies Identify any other emergency like unclaimed parcel etc Check Reporting of injuries, dangerous occurrences and near misses Calculation of AIR No of toolbox talks No of sub contractors trained No of walk-abouts taken No of persons trained in critical tasks No of inspections by management and observations raised

Accidents, incidents, non conformances and corrective and preventive action


Report accidents, injuries and near misses Carry out investigations Review risk assessment Recommend and implement control measures Set out additional improvement programs Record non conformances and take corrective and preventive action

Records and Records Management


Retention of records as per details given in P 11 and respective procedures

Inspection and Audit


Inspection at site by safety officer as per weekly program to be planned Check lists to be filled up by safety officers / engineers Walk about by Project Manager Internal safety audit by BU Safety managers as per plan. External audit IMS audit

ACT.
Monthly reports and returns Monthly review at site during review/safety meeting Review in ORM Review in management meeting Annual review in MDs Safety Workshop

Elements of Site Safety Plan


Company IMS (Safety) Policy Site Safety policy Site environment Hazard identification and Risk assessment and critical task analysis Law register Site objective and targets Improvement programs Structure at site / responsibility and authority Training programs Details of safety committee and safety meetings Documents required to be initiated / maintained with records

Operational Control Procedures (SHOP) Emergency Plans, actions and important telephone numbers Procedure for reporting of injuries, accidents, dangerous occurrences and near misses. Measurement of key performance indicators. Procedure for incident investigation. Methodology for non conformities and preventive and corrective action Details of records to be maintained and period for which retained Details of review of safety performance based on indicators Site rules

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