Ehs Hand Book-2017

EHS HAND BOOK- AHMED
INDEX PAGE NO, FROM TO

01. What is Safety?
02. Definition Hazard & Risk and Others.
03. HSEMS
04. Incident / Accident / Near Miss
05. Material Handling Equipment
06. Confined Space Entry
07. Permit to Work
08. Excavation
09. Scaffold
10. Demolition
11. Pilling
12. Housekeeping
13. Difference Sign & Symbols
14. Slip , Trips & Falls
15. Tools
16. Work at Height & Fall Protection
17. Ladder
18. Job Safety Analysis
19. Machinery Safety
20. Personal Protect Equipment
21. Ergonomics
22. MSDS
23. Gas Cylinder
24. Fire
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SAFETY
What is safety and why it is important?
Safety is the state of being "safe" (derived from French word sauf), the condition of being
protected against physical, social, spiritual, financial, political, emotional, occupational,
psychological, educational or other types or consequences of failure, damage, error,
accidents, harm or any other event which could be considered non-desirable. Safety can also
be defined to be the control of recognized hazards to achieve an acceptable level of risk. This
can take the form of being protected from the event or from exposure to something that
causes health or economical losses. It can include protection of people or of possessions.
OR
Freedom from unacceptable risk or harm is called safety.
SAFETY MEANS
S - Surveillance
A – Awareness
F - Follow Round the Year
E - Enthusiasm
T - Tactfully
Y - Yeomen Job
(Yeomen Job = doing a good job all round; working hard and competently)
Safety can also be defined to be the control of recognized hazards to achieve an acceptable
level of risk. This can take the form of being protected from the event or from exposure to
something that causes health or economical losses. It can include protection of people or of
possessions.
One should remember the acronym ‘’ 5M’’
1. M - Man
2. M - Machine
3. M - Material
4. M - Money
5. M - Mother Earth OR Environment
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Types of Safety
It is important to distinguish between products that meet standards, that are safe, and those
that merely feel safe. The highway safety community uses these terms:
Normative Safety
Normative safety is a term used to describe products or designs that meet applicable design
standards and protection.
Substantive Safety
Substantive or objective safety means that the real-world safety history is favorable, whether
or not standards are met.
Perceived Safety
Perceived or subjective safety refers to the level of comfort of users. For example, traffic
signals are perceived as safe, yet under some circumstances, they can increase traffic crashes
at an intersection. Traffic roundabouts have a generally favorable safety record, yet often
make drivers nervous.
Safety Measures
Safety measures are activities and precautions taken to improve safety, i.e. reduce risk related
to human health. Common safety measures include:
 Root cause analysis to identify causes of a system failure and correct deficiencies.
 Visual examination for dangerous situations such as emergency exits blocked because
they are being used as storage areas.
 Visual examination for flaws such as cracks, peeling, loose connections.
 Chemical analysis for determining strength of the material and suitability for the
application
 X-ray analysis to see inside a sealed object such as a weld, a cement wall or an airplane
outer skin.
 Destructive testing of samples
 Stress testing subjects a person or product to stresses in excess of those the person or
product is designed to handle, to determining the "breaking point".
 Safety margins/Safety factors. For instance, a product rated to never be required to
handle more than 200 pounds might be designed to fail under at least 400 pounds, a
safety factor of two. Higher numbers are used in more sensitive applications such as
medical or transit safety.
 Implementation of Safety Standards and Standard Operating Procedures so that
activities are conducted in a known way.
 Training of employees, vendors, product users
 Instruction manuals explaining how to use a product or perform an activity
 Instructional videos demonstrating proper use of products
 Examination of activities by specialists to minimize physical stress or increase
productivity
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 Government regulation so suppliers know what standards their product is expected to

meet.
 Industry regulation so suppliers know what level of quality is expected. Industry
regulation is often imposed to avoid potential government regulation.
 Self-imposed regulation of desired level of safety level.
 Statements of Ethics by industry organizations or an individual company so its
employees know what is expected of them.
 Drug testing of employees, etc.
 Physical examinations to determine whether a person has a physical condition that
would create a problem.
 Periodic evaluations of employees, departments, etc.
 Geological surveys to determine whether land or water sources are polluted, how firm
the ground is at a potential building site, etc.
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Definitions
Hazard - A hazard is the potential for harm. In practical terms, a hazard often is
associated with a condition or activity that, if left uncontrolled, can result in an injury
or illness.
Identifying hazards and eliminating or controlling them as early as possible will help
prevent injuries and illnesses.
OHSAS 18001 defines a hazard as a “source or situation with a potential for harm in
terms of injury or ill health, damage to the workplace, damage to the workplace
environment, or a combination of these.”
BS8800 defines a hazard as “a source or a situation with a potential for harm in terms
of human injury or ill health, damage to property, damage to the environment, or a
combination of these.”
RISK
BS8800 defines a risk as “the combination of the likelihood and consequences of a

specified hazardous event occurring.”
OHSAS 18001 defines a risk as a “combination of the likelihood and consequence(s) of a

specified hazardous event occurring.”
The Health and Safety Executive’s HSG65 management standard ‘Successful Health
and Safety Management’ defines a risk as “the likelihood that a specified undesired
event will occur due to the realization of a hazard by, or during, work activities, or by
the products and services created by work activities.”
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Risk= likelihood of happening X consequence
Definitions
Common Hazards and Descriptions
Chemical A chemical that exposes a person by absorption through the skin, inhalation,
(Toxic) injection or ingestion that causes illness, disease, or death. The amount of
Chemical exposure is critical in determining hazardous effects.
Check Material Safety Data Sheets (MSDS),
Chemical A chemical that, when exposed to a heat ignition source, results in

(Flammable) combustion. Typically, the lower chemical’s flash point and boiling point, the
More flammable the chemical. Check MSDS for flammability information.
Chemical A chemical that, when it comes into contact with skin, metal, or other
(Corrosive) materials, damages the materials. Acids and bases are examples of corrosives.
Explosion Self-explanatory.
(Chemical)
Explosion Sudden and violent release of a large amount of gas/energy due to

(Over Pressurization) significant pressure difference such as rupture in a boiler or
compressed
Gas cylinder
Electrical Contact with exposed conductors or a device that is incorrectly

(Shock/ Short Circuit) or inadvertently grounded, such as when a metal
ladder comes into contact With power lines. 60Hz alternating current
(common house current) is very dangerous because it can stop the heart.
Electrical Use of electrical power that result in electrical overheating or arcing to

(Fire) the point of combustion or ignition of flammables or electrical component
damage.
Electrical The moving or rubbing of wool, nylon, other synthetic fibers, and even flowing
(Static) liquids can generate static electricity this creates an excess or deficiency
of electrons on the surface of material that discharges (spark) to the ground
resulting in the ignition of flammables or damage to electronics or the body’s
nervous system.
Electrical Safety-critical equipment failure as a result of loss of power.

(Loss of Power)
Ergonomics Damage of tissue due to over exertion (strains and sprains) or repetitive motion.
(Strain)
Excavation Soil collapse in a trench or excavation as a result of improper or inadequate
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(Collapse) shoring. Soil type is critical in determining the hazard likelihood.
Fall Conditions that result in falls (impacts) from height or traditional walking
(Slip, Trip) surfaces (such as slippery floors, poor housekeeping, uneven walking surfaces
, exposed ledges, etc.)
Fire/Heat Temperatures that can cause burns to the skin or damage to other organs
Fires require a heat source, fuel, oxygen and chain reaction.
Mechanical /Vibration that can cause damage to nerve endings, or material fatigue
Vibration that results in a safety- critical failure.
Mechanical Failure Self-explanatory; typically occurs when devices exceed designed

capacity or are inadequately maintained.
Mechanical Skin, muscle, or body part exposed to crushing, caught-between, cutting,

tearing, shearing items or equipment.
Noise levels (>85 dB A 8 hr. TWA) that result in hearing damage or inability to
Communicate safety-critical information.
Radiation Alpha, Beta, Gamma, neutral particles, and X-rays that cause injury (tissue
(Ionizing) damage) by ionization of cellular components.
Radiation Ultraviolet, visible light, infrared, and microwaves that cause injury to tissue
(Non-Ionizing) by thermal or photochemical means.
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8
HSEMS – ELEMENT
1. Policy, 2. Organizing, 3. Planning & Implementation, 4. Evaluation, 5. Action for
Improvement.
Safety is a multi-disciplinary subject and it includes following disciplines:
• Finance
• Insurance
• Health
• Personnel
• Production
• Design
• Purchase
• Information technology (IT)
Three good reasons for preventing accidents in the workplace:
1) Ethical or Moral
2) Legal/social
3) Economic/Financial
Ethical and Moral Considerations
Most people would agree that, whatever risks they choose to take themselves, it is
unacceptable to put other people at risk, particularly when this is done without their
knowledge or consent. Put simply, everyone is entitled to feel confident that they will go
home in one piece! No-one wants to suffer an injury or to see a colleague injured.
Legal Requirements
Health and safety legislation places a number of duties on employers and employees. Failure
to carry out these duties can result in fines and, in extreme cases, imprisonment. We will look
at various legal requirements later in the course. However, the basic principle is that every
employee must take reasonable care for the safety of themselves and of others who may be
affected by their acts or omissions.
Economic
Financial penalties should be obvious. If you are injured and cannot work, insurance will
never fully compensate you for the financial loss.
There are two types of costs involved in any accident namely
1. Direct cost
2. Indirect cost
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Direct costs involve:-
 Lost time because of injured or deceased worker

 Damage to equipment, machinery, raw or finished material
 Medical or first-aid costs
 Time and materials to clean up after the accident
 Insurance, indemnity or compensation payment
 Court costs
 Fines
Indirect costs involve:-
 Lost time by other workers who stop work or reduce performance/supervisor or other
managers
 Weakened morale of employees
 Reputation or goodwill lost by the company
 Preparing accident reports, attending hearings, inquests courts
 Interference with production leading to failure to fill orders on time
 loss of bonuses, penalty payments and similar losses
 Cost incurred in selecting and training new employee in place of injured on
 Overtime payment
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Role of the health and safety policy in decision making

• Without active management involvement in health and safety any attempt at
organised accident prevention will be restricted and predominantly reactive
• The overall role of a policy is to provide direction for an organisation
• Will influence the decisions made by an organisation
• Many employers are required to have a health and safety policy by the national or
local legislation
• It is a key element of any occupational safety and health management system,
certified or voluntary
Key elements of a good health and safety policy
• Overall aims of the organisation in terms of health and safety performance

• Health and safety roles and responsibilities of individuals within the organisation
• Health and safety arrangements
• Reviewing the policy
• Standards and guidance relating to health and safety policy
An effective health and safety policy contains:
• A general statement of management commitment (What) - states the overall aims of

the organisation
• Details of the organisation (Who) - defining structure, role, relationships and
responsibilities of individuals towards health and safety
• Arrangements to control the risks(How) - expected to set the direction, scope and
actions of an organisation to manage health and safety
Resources for a good health and safety management system
The organisation should consider:
 The amount of support from senior management needed

 Financial
 Time
 People
 Technical
 Organisational
 Infrastructure and equipment
 The need for information, expertise, knowledge and training
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The duties of employers to provide a safe and healthy working environment arise from the
principles of negligence, contract, and the numerous specific statutory duties
Employer’s duties include:

 publish a health and safety policy
 arrange for the appointment of health and safety representatives
 establish a health and safety committee if requested by a recognized trade union
 appoint a competent person to evaluate risks and hazards
 arrange periodic risk assessments
 consult with employee health and safety representatives
 prevent risks
 inform staff of risks
 combat risks at source
 arrange protection from unavoidable risks
 provide safety training
 comply with the updated provisions concerning health and safety posters and leaflets
 monitor and improve safety arrangements
 provide health-risk surveillance
 adapt work to the individual especially with respect to the design of workplaces
 alleviate monotonous work
 develop a prevention policy
 appoint one or more competent persons to assist in undertaking preventative and
protective measures
 establish procedures to be followed in the event of serious and imminent danger to
persons working in the organization
 require persons at work who are exposed to serious and imminent danger to be
informed of the nature of the hazards and steps taken to protect them
 provide comprehensible and relevant health and safety information
 provide adequate health and safety training during working hours
 maintaining the workplace, equipment, devices and systems
 providing ventilation by sufficient quantity of fresh and purified air
 maintaining a reasonable temperature, and provision of thermometers
 ensuring suitable, sufficient and natural light so far as is reasonably practicable
 providing a clean workplace where waste materials must not be permitted to
accumulate
 providing sufficient floor area, height and unoccupied space
 providing suitable and sufficient sanitary conveniences at readily accessible places
Employee’s duties include:
The duty is often expressed as responsibilities to ensure that they:

 Take reasonable care for their own safety and that of other persons who may be
affected by their acts or omissions at work
 Comply with instructions given for their own safety and health and those of others
and with safety and health procedures
 Use safety devices and protective equipment correctly
 Promptly report any hazard that can cause accident
 Report any accident or injury to health that arises in the course of or in connection
with work.
 Follow all relevant instruction, information and procedure
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Culture Definition
component
Safety The organisation regards safety as sacrosanct and provides the licence
values to operate
Safety The organisation believes that safety makes commercial sense; that
beliefs individuals are not the sole causes of incidents; that the next accident is
waiting to happen
Common Risk assessment, cost-benefit analyses, accident analysis as well as
problem investigation, proactive search for problems in advance of incidents
solving
methods
Common Safety integral to design and operations practice, safety number one on
working meeting agendas up to Board level, chronic unease about safety
practices
Human factors which influence behaviour at work
Individual: Job:
Competence, skills, Task, work load,

personality, environment,
attitudes, risk display & controls
perceptions
procedures
Organisation:
Culture, leadership,
resources, work
patterns,
communications
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The organisation needs to provide:
• Clear and evident commitment

• An analytical and imaginative approach identifying possible routes to human factor
failure
• Procedures and standards for all aspects of critical work and mechanisms for
reviewing them
• Effective monitoring systems
• Incident investigation
• Adequate and effective supervision
Major considerations in the design of the job include:
• Identification and comprehensive analysis of the critical (high risk) tasks expected of
individuals
• Evaluation of required operator decision making
• Application of ergonomic principles
• Design and consistency of presentation of procedures and operating instructions
• Organisation and control of working environment
• Provision of correct tools and equipment
• Scheduling of work patterns
• Arrangements to cover for absence and procedures for emergencies
• Efficient and suitable communications
Individual differences are because of following factors:-
• Experiences in the womb
• Birth trauma
• Family influences
• Geographical location
• Pre-school influences
• Education - opportunities, quality, support
• Occupational factors - training and retraining
• Hobbies and interests
• Own family influences - marriage, children
• Ageing
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Maslow’s hierarchy of needs
Perception:-“The way that a person views a situation”
Factors that influence the effectiveness are:
• A boring, repetitive job may result in a lowering of the impact of a stimulus

• Warnings (or threats) may not be strong enough to get through the perceptual set
• Patterns of behaviour and habits can be carried from one situation to another
• Individuals can get 'used to' a stimulus
• Intense concentration on one task may make paying attention to another stimulus
difficult or impossible
• Some hazards may not be obvious or they are hidden
• The presence of hazards may be masked by environmental issues
Process of perception :-
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Errors and violations
There are two different types of human failure:
Errors and violations
• A human error is an action or decision that was not intended, which involved a
deviation from an accepted standard, and which led to an undesirable outcome
• A violation is a deliberate deviation from a rule or procedure
Errors fall into three categories:
1) Slips
2) Lapses
3) Mistakes
Routine violations
• Where breaking the rules or procedure has become the normal way of working
• A quicker way to work or because the rules are seen as too restrictive
Situational violations
• May occur with pressures from the job: time pressure, extreme weather conditions,
wrong equipment, etc.
• Roof work may continue without edge protection, because the correct equipment has
not been provided
Exceptional violations
• Occur when something has gone wrong

• A decision has to be made to solve the problem and that might involve breaking a rule
and taking a risk
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The influence of peers
• Nearly all human beings need the company and social acceptance of their fellows
• The social group is formed out of individuals with common beliefs, interests,
expectations, etc.
• The work group is different to the social group
• Individual behaviour may be strongly influenced by their peers and personal choice
may be changed by the peer pressure
Individual factors: Job factors: Organisational factors:
 Increase skill and  Correct ergonomic  Good work planning

competence levels design of tools and to avoid high work
 Select staff equipment pressure
according to their  Prevent disturbances  Adequate safety
capabilities and interruptions systems and barriers
 Provide health  Provide clear  Respond quickly to
surveillance instructions. previous incidents
wherever necessary  Maintain equipment  Consultation rather
 Job rotation to to a suitable than information
prevent boredom standard  Clear identification of
 Minimise exposure to responsibilities
unpleasant working  Thorough
conditions such as management training
noise, heat, adverse  Create positive health
weather etc. and safety culture
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Communication
The “Four C’s”

• Methods of control
• Means of securing co-operation
• Methods of communication
• Competence of individuals
Communication (from Latin "communis", meaning to share) is the activity of conveying
information through the exchange of thoughts, messages, or information, as by speech,
visuals, signals, writing, or behavior.
It can also be defined as any act by which one person gives to or receives from another
person information about that person's needs, desires, perceptions, knowledge, or affective
states. Communication may be intentional or unintentional, may involve conventional or
unconventional signals, may take linguistic or nonlinguistic forms, and may occur through
spoken or other modes.
Communication requires a sender, a message, and a recipient, although the receiver doesn't
have to be present or aware of the sender's intent to communicate at the time of
communication; thus communication can occur across vast distances in time and space.
Communication requires that the communicating parties share an area of communicative
commonality. The communication process is complete once the receiver has understood the
message of the sender.
SENDER RECEIVER
MEDIUM
General principles of communication:

• Communicate in a form capable of being understood by the recipient
• Use open ended questions
• Use closed questions to confirm
• Use clear and unambiguous terms
• Be assertive but not aggressive
• Keep content concise
• Ensure understanding
• Check to ensure understanding
• Budget time to encourage feedback
• Direct themselves towards the intended recipient
Barriers to effective communications
• Noise/distractions
• Complexity of information
• Language/dialect of the speaker
• Sensory impairment
• Ambiguity
• Use of technical jargon
• Mental difficulty
• Inexperience on the part of the recipient
• Lengthy communication chains
• Inattention
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Training
A health and safety training programme should be implemented for all workers from general
workers to director level. It Should include:
 Specialist training
 Internal and external courses
 Formal and informal training
Effects and benefits of training
Benefits to worker
• Better understanding and involvement raises staff morale/job satisfaction

• Understanding of relevance of systems of work and controls reduces risk
• Understanding of welfare arrangements aids health, safety and hygiene
• Allows worker to reach experienced worker standard more quickly
• Increases flexibility of staff
Benefits to employer
• Reduces accident frequency and severity

• Reduces injury related absenteeism
• Reduces claims and insurance premiums
• Reduces the chance of prosecution
• Increases profits/benefit
Induction training for new workers
Key health and safety topics to be covered
• Review and discussion of the safety policy

• Specific training requirements
• Fire and emergency procedures
• Welfare facilities
• First-aid procedures and facilities
• PPE provisions - limitations, use and maintenance
Refresher training
• Regular refresher training

• Reinforce employer’s desired approach
• Common refresher period is three years
• Provided to managers and workers
 Job change/process change

• Introduction of new substances/processes
• Changes in working procedure
• Changes in work patterns
• Review of risk assessments
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 Introduction of new legislation
• Employers have a duty to bring to the attention of workers specific changes in

legislation
• May have an effect on their safety or the safety of others
• Changes that may affect personal health and safety
 Introduction of new technology
• Will often require the adoption of new work practices

• For example, improvements in manual handling by using mechanical aids
• Such training will include developing skills to interpret equipment control layouts and
data display
Specific health and safety training
• Safe systems of work

• Equipment training
• PPE training
• Fire training
• Health and safety inspections
• First-aid training
First-aid training
First-aid
First aid is the provision of initial care for an illness or injury. It is usually performed by
non-expert, but trained personnel to a sick or injured person until definitive medical treatment
can be accessed. Certain self-limiting illnesses or minor injuries may not require further
medical care past the first aid intervention. It generally consists of a series of simple and in
some cases, potentially life-saving techniques that an individual can be trained to perform
with minimal equipment.
An employer must make an assessment to determine the first-aid needs, consideration should
be given to:
 Different work activities

 Difficult access to treatment
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 Workers working away from employer's premises

 Workers of more than one employer working together
 Provisions for non-workers
 Work out the number and size of first-aid boxes required
 Additional facilities
Role of first-aiders
• Give immediate assistance to casualties with workplace injuries or illness

• To summon an ambulance or other professional help
Selection of first-aiders
• Reliability
• Disposition
• Communication skills
• Aptitude and ability to learn
• Ability to cope with stressful situations
• Availability at short notice
Number of first-aiders
• The employer must ensure that adequate numbers of "suitable persons" are provided
to administer first-aid
• "Suitable persons" are those who have received training and acquired competence to
an approved level
• All relevant factors have to be taken into account when deciding how many "suitable
persons" will be needed.
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INCIDENT / NEARMISS / ACCIDENT
Incident
घटना
Near miss
Accident
बाल-बाल
दु घघटना
बचना
ILL Health
Fatal Loss time First Dangerous Restricted
injury(LTI) aid occurance work case
R Cases R
R NR R NR
• R
• R
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Incident :-An unusual and unexpected occurrence, which either resulted in or had the
potential to result in injury to personnel, significant damage to property, adverse
environmental impact, a major interruption of process operation or loss of materials(either
raw, semi-finished or finished).
Near Miss :-An occurrence in which an accident (property damage, environmental Impact
and human loss or an operational interruption) could have passively resulted if circumstances
had been slightly different .
Accident :-An unintended, unplanned and undesired occurrence arising out of or in the
course of employment of a person resulting in injury.
Fatal :-Synonyms are deadly, mortal, lethal. Fatal accident is a event that resulting in or
capable of causing death a fatal accident.
Dangerous Occurrence :-A dangerous occurrence is a situation where there is, or could
have been, an immediate and significant risk to any person. There does not need to be any
injury for an event to be a dangerous occurrence.
Examples of dangerous occurrences include:
1. The collapse or partial collapse of a building, floor, wall or ceiling.
2. An explosion, fire or escape of a hazardous substance.
3. An electrical short circuit or malfunction.
4. A flood of water, rock fall, or collapse of ground.
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Incident investigation
Why We Investigate Incidents, and not just “Accidents” ?
1. Demonstrate our commitment to safety - Increase employee’s confidence in safety

2. Spot deficiencies in safety management - Identify systems and conditions that could
contribute to other incidents
3. Prevent recurrence - Take appropriate action - Communicate lessons learned
Reasons of accident
Only 4% accidents are because of unsafe conditions and equipments and rest 96% are
because of unsafe acts
HEINRICH TRIANGLE
Iceberg Analogy
Fatalities
Lost Time Injuries
Medical treatment
case/ First aid case
Unsafe Acts
Unsafe Conditions
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Fatalities
Lost Time Injuries
Medical treatment case/ First aid case
Medical Treatment
First Aid Cases
Causes of Incidents
Direct Cause: Immediate events or conditions that caused the accident.

Contributing Cause: Major unintended contributor to the incident, that if eliminated
would have either prevented occurrence or reduced its severity/ frequency
Root Cause : Fundamental, underlying, system-related reason that identifies a correctable
failures in management systems. There could be more than 1 root cause.
Core Analytical Methods
• Events and causal factors charting and analysis
• Barrier analysis
• Change analysis
• Root cause analysis
Advanced Analytical Methods
• Analytic Trees
• Management Oversight and Risk Tree Analysis (MORT)
• Project Evaluation Tree (PET) Analysis
Other Analytical Methods
• Time Loss Analysis
• Human Factors Analysis
• Integrated Accident Event Matrix
• Failure Modes and Effects Analysis
• Software Hazards Analysis
• Common Cause Failure Analysis
• Sneak Circuit Analysis
• Materials and Structural Analysis
• Design Criteria Analysis
• Accident Reconstruction
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Who Should Investigate Incidents?
1. Line management is responsible for investigating all incidents.

2. Safety officers are there to help, not do line managers’ job.
The Incident Investigation Process
1. Make initial response and report

2. Form investigation team
3. Determine the Facts
4. Determine the key factors
5. Determine systems to be strengthened
6. Recommend corrective and preventive actions
7. Document and communicate the finding
8. Follow up
Initial Response
1. Coordinate with emergency response team

2. Carry out initial investigation at site
3. Identify witnesses - interview as soon as possible
4. Control any secondary incidents
5. Preserve evidence and the scene of incidents
Control of Secondary Incidents
It is the primary responsibility of emergency response team

• Containment if control cannot be achieved
• Mitigation (reduction) of effect on people, equipment, environment
Preserve Incident Scene
Primary responsibility of management or incident investigation team (if formed).
1. Remove all person from the incident scene except emergency response people.
2. Secure the area - this may require…….
 Cordoning off the area with rope / barricades

 Locking doors and gates
 Posting warning sign
 Posting security personnel
 Preserve evidence
Communicating with External Agencies
Usually done by most senior company executives - not by the investigating team.
•Who is to communicate?
•What to communicate?
•When to communicate?
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Consider -
•Impact to business
•Impact to image
•Impact to employee morale
Initial Response and Report
From the initial response and report (the PIR), management can identify those incidents that
require a comprehensive investigation and supply the necessary resources. The report should
be
 Brief
 Limited to known facts ( Date, time, what happened, immediate action taken)
 Who is to do the investigation?
 Formation of Investigation Team
 Select the team members (skills and knowledge?)
 Define the responsibilities (terms of reference)
 Define the scope (boundaries) of the investigation
Chair Person’s Responsibilities
Call and preside over meetings

Keep investigation focused for prompt and complete results.
Ensure participation of members
Ensure report is complete
Communicate with management about investigation.
Funneling Information to Obtain Facts
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Categories to Explore
•Physical Factors
•Human factors
•Operating system factors
Physical
•Weather
•Chemical
•Tools
•Personnel protective equipment
Human
•Employee attitude and motivation
•Supervision practices and standards
•Company culture
Operating system
•Training
•Documentation
•Rules/ Procedures
•Preventive Maintenance
•Job safety analyses
•Previous results (Audits & Observations)
•Communication
Three Main Analysis Methods

•Why Tree analysis
•Barrier analysis
•Event and Causal analysis
Why Tree analysis

Determine the key factors Why – Tree
-In order drive root cause of a failure, whether chronic or sporadic, we use tool known as a
WHY – Tree
- It’s called a “Why “ tree because we keep asking “Why “ to get the root causes
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Why Tree Symbols
Steps in Building a “WHY” Tree

Step 1. Bring as much information as is available about the failure to the Why Tree meeting.
Have photos, sketches, and/or samples of the failure.
Step 2. Show the team a sample Why Tree and give them an explanation of how one is built.
Step 3. Write a statement about the failure, describe it in some detail. Spend ample time up
front discussing what the “failure” is, so all understand and agree.
Step 4. List the observations that have been collected on tear sheets (doing some of this in
advance speeds up the process). Prioritize them based on their likely connection to the failure.
Step 5. Select a few (3-5) of the highest priority observations and put them on the Why Tree
Step 6. Starting with the highest priority one, hypothesize causes of these observations by
asking “Why or How Can”. You can also say “caused by” when moving down the tree from
one cause to another.
Step 7. Verify the hypotheses as true or not. Strike through untrue hypotheses but keep them
on the Tree to show they were considered and checked.
Step 8. Continue this process of generating, verifying, and ranking hypotheses. If the
necessary information is not available in the meeting room, either stop the process and go
validate the hypothesis or switch to another branch of the tree and validate later.
Step 9. Stop when you arrive at System Key Factors.
When choosing between asking “Why” and “How Can”, use the one which links you back to,
or which best leads toward a cause of, the original failure event.
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Barrier Analysis
30
Barrier Analysis
Main Elements
• Barrier Analysis-Most frequently used & most common in industry. Good for single events
where time is not a major factor in what happened. Simple logic.
• Threats, hazards or forces (energy) that can do harm
• Targets (People?) or things of value that can be harmed
• Barriers or safeguards
•Trace or route of threat's contact or influence on Target
Barrier analysis is used to identify hazards associated with an accident and the barriers that
should have been in place to prevent it.
• A barrier is any means used to control, prevent, or impede the hazard from reaching the
target i.e. Man, Machine, Material or Environment
Barrier analysis addresses:

• Barriers that were in place and how they performed
• Barriers that were in place but not used
• Barriers that were not in place but were required
• The barrier(s) that, if present or strengthened, would prevent the same or similar accidents
from occurring in the future.
Barrier Analysis - Strategies

• Eliminate the Hazard
• Reduce the Hazard
• Modify the Release
• Separate in Time or Space
• Isolate the Target or the Hazard
• Strengthen the Target
• Reduce the Effect
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Action Taken Report on Accident Investigation
Management is responsible for acting on the recommendations in the accident investigation

report. The health and safety committee, if you have one, can monitor the progress of these
actions.
Follow-up actions includes:
• Respond to the recommendations in the report by explaining what can and cannot be
done (and why or why not)
• Develop a timetable for corrective actions
• Monitor that the scheduled actions have been completed
• Check the condition of injured worker(s)
• Inform and train other workers at risk
• Re-orient worker(s) on their return to work
Action Plan
By using the results from the Analysis, the optimum method for correcting the situation (or
preventing a future occurrence) is determined and an action plan developed. The plan should
include, as appropriate: the items to be completed, document changes, any process,
procedure, or system changes required, employee training, and any monitors or controls
necessary to prevent the problem or a recurrence of the problem. The action plan should also
identify the person or persons responsible for completing each task.
Actions to be Completed
• List all of the activities and tasks that must be accomplished to either correct the
existing problem or eliminate a potential problem.
• For a CAPA program to be effective, it is very important to take a very global
approach. Make sure to identify all actions that will be required to address everything
related to the situation.(e.g. in the training situation described earlier, the root cause
was a flaw in the training program)
• Document or Specification changes List any documents that will be modified and
describe in general terms what the modifications will be.
• Process, Procedure, or System changes If any changes to processes, procedures, or
systems must be made they are described.
• Enough detail should be included so that it is clearly understood what must be done.
• The expected outcome of these changes should also be explained.
Employee Training
Employee training is an essential part of any change that is made and should be part of
the action plan. To assure that the actions taken will be effective, any modifications made
to documents, processes, etc. must be effectively communicated to all persons or
departments that will be affected.
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Action Plan form
• This should provide a set of written procedures that detail all of the actions that must
be done to resolve the problem and prevent it from recurring. This includes corrective
and preventive activities, document changes, training, etc.
• The person or persons responsible and an expected completion date should also be
entered on the form.
Documentation
• All documents or other specifications that have been modified are listed. Typically the
documentation would be attached to a final printed report of this CAPA action. This
will facilitate verification of the changes for the follow up.
Follow Up
• One of the most fundamental steps in the CAPA process is an evaluation of the
actions that were taken. Several key questions must be answered:
• Have all of the objectives of this CAPA been met? (Did the actions correct or prevent
the problem and are there assurances that the same situation will not happen again?)
• Have all recommended changes been completed and verified.
• Has appropriate communications and training been implemented to assure that all
relevant employees understand the situation and the changes that have been made?
• Is there any chance that the actions taken may have had any additional adverse effect
on the product or service?
Verification Results
• The implementation and completion of all changes, controls, training, etc. must be
verified. The evidence that this has been done must be recorded. Appropriate
information should have been entered to document that all actions have been
completed successfully.
• Results / Effectiveness of the Actions
• Another important aspect of any CAPA action is to make sure that the actions taken
were effective. A thorough evaluation must be done to make sure that the root cause
of the problem has been solved, that any resulting secondary situations have been
corrected, that proper controls have been established, and that adequate monitoring of
the situation is in place. This evaluation must also include an investigation to
determine if the actions taken could result in any other adverse effects. This
investigation and the results should be documented.
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Material Handling Equipment
To provide guidelines
• Handling Materials manually

• Using moving machinery like
 Fork Lift Trucks

 Conveyors
 Cranes and Derricks
 Tower Cranes
 Overhead and Gantry Cranes
 Mobile Cranes
 Passenger Lifts and Material Hoists
Associated Hazards
 Poor site layouts

 Falls from Vehicle
 Height Restriction
 Overturning
 Collisions
 Striking people and equipment
Manual Lifting
 Not to carry loads above capacity

 Loads shall not exceed 20 kg. For men, 15 kg. For women
 Mechanical lifting is preferable
 Safe lifting postures
General Precautions
 The Load is safe and secured while lifting

 Slinging method is proper
 Lifted load not exceeding safe working load
 Load is so slung, that it will not collapse or does not damage the sling
 No load is unattended when power is on or load is suspended above machinery
 No person shall ride on the suspended load or lifting machinery
 All persons shall strictly use helmets and safety shoes
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35
Fork Lift Trucks
Conveyors
• Stop switch at operator’s station and near motor

• Emergency Switch – pull chord – must be operative all time
• Proper interlock to start
• Screw conveyors to be guarded to prevent contact
• Proper guard to be provided, if required to work below conveyor
• Riding or crossing-over a conveyor is not allowed
• All pulleys, belt nips, idlers are to be guarded
36
SAFETY DEVICES
 HOOK LATCH
 BOOM LIMIT SWITCH
 BOOM ANGLE INDICATOR
 OVER HOIST LIMIT SWITCH
37
38
Wire Ropes Slings - Maximum SWL (in KG.) (Double Leg Wire Rope Sling)
Nominal Dia. of Rope INCLUDED ANGLE
0 Deg. 30 Deg. 60 Deg. 90 Deg.
3/8” 10 mm 1200 1150 1100 850
½” 13 mm 2000 1900 1750 1400
¾” 19 mm 4450 4300 3850 3150
1” 25 mm 7700 7450 6650 5950
1 ¼” 32 mm 12500 11900 10850 8850
1 2/4” 38 mm 17800 17200 15900 12600
1 ¾” 44 mm 28000 26600 24200 19700
2” 50 mm 36000 34600 32100 25900
2 ¼” 56 mm 46000 44600 39800 32500
2 ½” 62 mm 56000 54000 48400 39500
2 ¾” 68 mm 68000 65400 58200 48000
3” 75 mm 82000 79200 71000 57900
Note: Increasing the vertical/included angle between slings decreases the loading
capacity of the sling.
Removal from service
 Each wire rope used in hoisting or lowering or in pulling loads shall consist of
One continuous piece without knot or splice.
 Wire rope shall not be used if in any length of eight diameters, the total
number of visible broken wire exceeds 10 per cent of total number of wires or
if the rope shows other signs of excessive wear, corrosion or defect.
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 In pendants or standing ropes, there should not be more than 3 broken wires
in one rope lay. (A rope lay is the length along the rope in which one strand
makes a complete revolution around the rope).
 Near attached fittings there should not be any broken wires.
 Wear on the surface of the rope should not be more than 1/3 of the diameter
of the wire.
 Reduction in diameter of the rope due to core failure, abrasion, etc. should
not be more than :
1.0mm for ropes up to - 19 mm dia
1.5 mm for ropes of 22 - 28 mm dia
2.0mm for ropes of 32 - 38 mm dia

 Rope stretch should not be more than 150 mm per 30 M length in the six
strand wire ropes.
 No bird caging, kinks or core protrusion shall exist in the wire rope.
40
Rope Replacement Criteria based on Visual Inspection
41
Rope replacement criteria based on numberof broken wires
42
NATURAL ROPE AND SYNTHETIC FIBRE
All splices in rope slings shall be made in accordance with manufacturer's recommendation.
Spliced fiber rope slings shall not be used unless they have been spliced as per the
manufacturer's recommendation.
Knots shall not be used in lieu of splices.
Natural and synthetic fiber rope slings shall be immediately removed from service, if any,
of the following conditions are present.
Abnormal wear.
Powdered fibres between strands.
Broken or cut fibres.
Variations in the size or roundness of strands.
Discoloration or rotting.
Distortion of hardware in the sling.
Synthetic Webbing (Nylon, Polyester and Poly Propylene)
 Synthetic webbing shall be of uniform thickness and width and selvage edges
shall not be split from the webbing width.
Fittings shall be –
 of a minimum breaking strength equal to that of the sling

 free of all sharp edges that could in any way damage the webbing.
 Attachment of end fittings to webbing and formation of eyes.
 Stitching shall be the only method used to attach end fittings to webbing and to
form eyes. The thread shall be in an eyes pattern and contain a sufficient number
of stitches to develop the full breaking strength of the sling.
Environmental Conditions
 When synthetic web slings are used the following precautions shall be taken.
 Nylon web slings shall not be used where fumes, vapors, sprays, mists or liquid of
acids or phenol are present.
 Polyester and polypropylene web slings shall not be used where fumes, vapors,
sprays, mists or liquids of caustics are present.

Removal from Service
 Synthetic web slings shall be immediately removed from service if any of the following
conditions are present.
 Acid or caustic burns;

 Melting or charring of any part of the sling surface;
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 Snags, punctures. tears or cuts;

 Broken or worn stitches; or Distortion of fittings.
CHAIN BLOCKS / HOOKS / PULL LIFTS
Chain blocks of proper lifting capacity supported by Test Certificate should be used for
lifting known loads.
Chain block must be checked, and tested periodically. It should be lubricated before
every use.
No cannibalizing should be done on chain block.
Chain blocks should be tested for slip by suspending safe load.
It should operate freely and the chain should not come out of pulleys.
The anchorage should be strong and rigid.
They should be checked for cracks, excessive wearing, elongation, etc. Hooks opened
out should not be used.
No chain block / puller which has been tampered, be used unless it is thoroughly checked
and tested by competent person.
Chain block / puller must be checked if stored for longer time, by subjecting to shock load,
to observe slipping of load, jamming of links etc.
Use wire rope / sling for tying in (do not use Manila or Fiber Rope for tying purposes)
SHACKLES
The inside width of the shackle shall not be greater than that listed that stipulated in IS code
Pins should not be bent; pins shall not be replaced with bolts.
Removals from service
 Discard the shackle if there is any deformation on anybody of the shackle.

 Discard the shackle if the shackle pin is bent, cracked or twisted.
 Discard the shackle if the threads in the body or on the pin are damaged.
 Discard the shackle if the shackle pin is not fitting properly in the body.
 Shackles worn in the crown or the pin more than 10% of the original diameter should
be replaced.
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Determining capacity 2 leg / 3 leg / 4 leg bridle hitch
45
46
CONFINED SPACE
Confined Space means any space having a limited means of egress, which is subject to the
accumulation of the toxic or flammable contaminants or has a Oxygen deficient atmosphere.
It may also have moving machinery / electrical or other accidental / physical / engulfment
hazards.
Examples of confined spaces are: Pits, Dikes, Excavations, Cable Tunnels, Sewers, Vessels,
Storage Tanks, Gas Holders, Cyclones, Dust Catchers, Electrostatic Precipitators, Scrubbers,
Silos, Vats, Boilers, Ducts, Pipe Lines, Furnaces, Conveyor tunnels, Manholes, Hoppers etc.
A Confined Space is any space having the following characteristics:
1. Large enough or so configured that an employee can bodily enter and perform assigned
work.
2. Has limited or restricted means for entry or exit.
Confined-space openings are limited primarily by size and location. Openings may be small
in size and may be difficult to move through easily. However, in some cases openings may
be very large; for example, open-topped spaces such as pits or excavations. Entrance and exit
may be required from top, bottom, or side. Size or location may make rescue efforts difficult.
3.Is not designed for continuous employee occupancy
Most confined spaces are not designed for employees to enter and work on a routine basis.
They may be designed to store a product, enclose materials and process, or transport products
or substances. Therefore, occasional employee entry for inspection, maintenance, repair,
clean up, or similar tasks, is often difficult and dangerous. The danger associated with entry
may come from chemical or physical hazards within the space.
Associated Hazards:
Fatalities or severe injuries may occur as a result of the following:
(a) Oxygen deficiency in the confined space which may be caused by -
(i) slow oxidation reactions of either organic or inorganic substances;
(ii) rapid oxidation (combustion);
(iii) the dilution of air with an inert gas;
(iv) absorption by grains, chemicals or soils; or
(v) physical activity.
(b) Oxygen excess in the confined space which may be caused by a leaking oxygen supply
fitting such as in gas cutting or heating equipment.
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(c) The presence of contaminants on surfaces or in the atmosphere. Contaminants may be in

the form of solids, liquids, sludges, gases, vapours, fumes or particulates. The sources of
atmospheric contaminants encountered may include -
(i) the manufacturing process;
(ii) the substance stored or its by-products (for example, disturbing decomposed organic
material in a
tank can liberate toxic substances such as hydrogen sulphide, while biological hazards such
as
bacteria, viruses or fungi may also be present); and
(iii) the operation performed in the confined space (for example, painting with coatings
containing toxic
or flammable substances, and welding or brazing with metals capable of producing toxic
fumes).
(d) Operation of moving equipment (for example, being trapped by augers, crushed by
rotating or moving parts such as conveyor belts).
(e) Uncontrolled introduction of steam, water, or other gas or liquid.
(f) Suffocation by solids (for example, grain, sand, flour and fertilizer).
(g) Electrocution.
(h) Explosion or fire.
Additional factors undertaking work in confined spaces may greatly increase the risk of
injury from hazards, such as –
 Noise, which may be caused by hammering or the use of equipment within the
confined space;
 Temperature, either high or low, which can result from the work process or the
weather conditions, or where appropriate ventilation or appropriate clothing is not
supplied or worn;
 Radiation within a confined space (for example, from X-rays, radiation gauges,
isotopes, lasers and welders);
 Manual handling
 Slip, Trip, Fall
 Bad odour
 Biological hazard
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Definitions:
(a) AEL and LEL: Acceptable exposure limits(AEL) and lower exposure limit (LEL)
(b) Attendant: A person who must be in continual visual or hearing contact with
personnel inside the permit-required confined space. An attendant must be adequately
trained to monitor the activities of personnel inside the space and must perform all
attendants, duties assigned in the procedure of working in Confined Space .
(c) Competent Person: A person declared by Chief Inspector of Factories as competent
under Section 36 of Factory Act 1948 based on qualification, experience and facilities
available at his disposal to certify a confined space as safe to work based on test /
examination of atmosphere carried out by himself.
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(d) Contaminant : any dust, fume, mist, vapour, gas or other substance in liquid or solid
form, the presence of which may be harmful to health and safety.
(e) Entrant: A person who has been authorized by his/her employer to enter a confined
space to perform any activity.
(f) Entry Supervisor: The person responsible for determining if acceptable entry
conditions are present in a confined space where entry is planned, for authorizing
entry and overseeing entry operations, and for terminating entry as required by this
procedure.
(g) Stand-by person : a competent person assigned to remain on the outside of, and in
close proximity to, the confined space and capable of being in continuous
communication with and to observe those inside, if practicable. In addition, where
necessary, initiate rescue procedures and operate and monitor equipment used to
ensure safety during entry and work in the confined space.
General Requirement:
(a) All the departments shall evaluate the workplace using the checklist attached with this
procedure to identify the confined spaces. Department shall maintain a documented master
list of confined spaces and review this list at least annually to update it. Confined spaces will
have a display “Confined Space – Do not enter without permit”.
(b) All employees shall be made aware of these confined spaces and associated hazards.
(c) An entry permit as per approved format is required to enter a confined space that has one
or more of the following characteristics..
(i) Contains or has the potential to contain hazardous air contaminants like CO, NH3,
Acid/Alkali fumes, etc.
(ii) Contains flammable materials/ vapor which can catch fire due to spark or static
charges.
(iii) Due to internal configuration of the space an entrant could be trapped or asphyxiated
(lack of oxygen) or
(iv) Contains any other site specific serious safety or health hazard as identified by the
department.
Example: Hoppers, Boilers, Tanks, Pits, Vessels, Gas Holder, Cyclone, Electrostatic
Precipitators, Scrubbers, Silo, Pipe Line, Oil Cellars, Coke Oven Battery Cellars, Blast
Furnace Stoves, etc.
(d)The authorized permit from the competent person should be taken in written in the
standard entry permit form. Two parts of the form must be filled up as per instructions given
below:
Part-I – Must be authorized and signed by competent person based on test/examination

conducted by him indicating his findings in the format. He shall also recommend periodicity
of work area parameter checking, intermittently, if required.
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Part-II – Based on the approval and authentication by competent person in Part-I,

departmental site in charge will issue the permit for work inside the confined space,
indicating checks carried out, to the working agency by filling format in Part-II.
(e)The person responsible for executing the job inside the confined space will maintain a
register-indicating list of persons entering into the confined space with Time In and Time
Out by each individual.
(f)The owner department shall ensure that work permit and Clearance for the job to be done
in the confined space are duly provided separately like work permit for Electrical
Installation, Gaseous Hazard Area, Working at Height, Hot Jobs etc.
RISK ASSESSMENT:
(a) An employer shall ensure that a risk assessment is undertaken by a competent person
before carrying out work involving entry into a confined space. As far as practicable the
assessment shall be in writing and take into account at least the following:
(i) the nature of the confined space;
(ii) the work required to be done, including whether it is necessary to enter the confined
space;
(iii) the range of methods by which the work can be done;
(iv) the hazards involved and associated risks;
(v) the actual method selected and plan proposed; and
(vi) emergency and rescue procedures.
(b) The employer shall ensure that the assessment is revised whenever there is evidence to
indicate that it is no longer valid.
(c) Risk factors: Factors to consider when undertaking a risk assessment include -
(i) arrangements for rescue, first aid and resuscitation;
(ii) the number of persons occupying the space;
(iii) the number of persons required outside the space to maintain equipment essential for the
confined space task, to ensure adequate communication with and observation of the persons
within the confined space, and to properly initiate rescue procedures .
(iv) all proposed operations and work procedures, particularly those that may cause a change
in the conditions in the confined space;
(v) the soundness and security of the overall structure and the need for illumination and
visibility;
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(vi) the identity and nature of the substances last contained in the confined space;
(vii) the steps needed to bring the confined space to atmospheric pressure;
(viii) the atmospheric testing to be undertaken and the parameters to be assessed before the
entry permit is issued;
(ix) all hazards which may be encountered (for example, entrapment);
(x) the status of fitness and training of those persons involved in confined space work;
(xi) adequate instruction of those persons in any work procedure required, particularly those
which are unusual or non-typical, including the use and limitations of any personal protective
equipment and mechanical or other equipment to be used;
(xii) the availability and adequacy of appropriate personal protective equipment, protective
clothing and rescue equipment for all persons likely to enter the confined space;
(xiii) whether signs indicate that entry is permitted only after signing the entry permit, in a
manner appropriate to the persons at the workplace;
(xiv) the need for additional protective measures, for example -
(a) prohibition of hot work in adjacent areas,

(b) prohibition of smoking and naked flames within the confined space and, where
appropriate, the
(c) adjacent areas,
(d) avoidance of contamination of breathing atmosphere from operations or sources
outside the confined space, such as from the exhaust of an internal combustion
engine, and
(e) prohibition of movement of equipment such as forklifts in adjacent areas, and
(f) prohibition of spark generating equipment, clothing and footwear;
(xv) whether cleaning in the confined space is necessary; and
(xvi)whether hot work is necessary.
CONTROL MEASURES
(a) If a risk assessment identifies a risk to health or safety arising from work involving entry
into a confined space, the employer shall eliminate or minimize the risk.
(b) Hierarchy of control measures
A hierarchy of control measures to eliminate or minimize the risk should be followed in the
priority order listed and consists of -
(i) elimination;
(ii) substitution;
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(iii) isolation;
(iv) engineering controls;
(v) administrative controls; and
(vi) use of personal protective equipment.
(c) Review of control measures:
Control measures should be carefully reviewed and improved, extended or replaced as

necessary to ensure adequate control. Reviews should take place at regular intervals or as
indicated by the assessment report, in the event of any significant change to plant or process.
(d) Prior to any person entering a confined space, the employer shall ensure that where
practicable all potentially hazardous services, including all process services, normally
connected to that space are isolated in order to prevent:
(i) the introduction of any materials, contaminants, agents or conditions harmful to people
occupying the confined space; and
(ii) the activation or energizing in any way of equipment or services which may pose a risk to
the health or safety of persons within the confined space.
(e) Methods of isolation from contaminants :
Where required by a confined space should be isolated before entry is permitted. The method
of isolation should be in accordance with one of the following methods or by an alternative
method ensuring equivalent security:
(i) Removal of a valve, spool piece, an expansion joint in piping leading to, and as close as
practicable to, the confined space and blanking or capping the open end of the piping leading
to the confined space. The blank or cap should be identified to indicate its purpose. Blanks or
caps should be of a material that is compatible with the liquid, vapour or gas with which they
are in contact. The material should also have sufficient strength to withstand the maximum
operating pressure, including surges, which can be built up in the piping.
(ii) Insertion of a suitable full-pressure spade (blank) in piping between the flanges as close
as practicable to the confined space. The full-pressure spade (blank) should be identified to
indicate its purpose.
(iii) Where neither of the methods described in Items (i) and (ii) is practicable, isolation by
means of closing and locking, or closing and tagging, or both, of at least two valves in the
piping leading to the confined space. A drain valve between the two closed valves should also
be locked open or tagged open to atmosphere as part of this method.
f) Methods of isolation from moving parts Before entry is permitted to any confined space
that in itself can move, or in which agitators, fans or other moving parts which may pose a
risk to personnel are present, the possibility of movement should be prevented by using one
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of the methods described below or by alternative methods offering equivalent security.

Equipment or devices with stored energy, including hydraulic, pneumatic, electrical,
chemical, mechanical, thermal or other types of energy, should be reduced to a zero energy
condition. The person entering the confined space should proceed as follows:
(i) Physically disconnect the electric power from the piece of equipment whenever possible.
(ii) The person entering the confined space or a competent person authorized in writing by
the employer should place a lock or tag, or both, on the open circuit breaker or open isolating
switch supplying electric power to equipment with hazardous moving parts, to indicate that a
person is in a confined space and that such isolation should not be removed until all persons
have left the confined space. When a lock is used, the key should be kept in the possession of
the person making entry or the competent person. Spare keys should not be accessible except
in cases of emergency.
(iii) Where a power source cannot be controlled readily or effectively, a belt or other
mechanical linkage should be disconnected and tagged to indicate that a person is in a
confined space and that the belt or linkage should not be reconnected until all persons have
left the confined space.
(iv) Where the methods described in Items (i) and (ii) are not practicable, moveable
components should be locked, and switches, clutches or other controls should be tagged to
indicate that a person is in a confined space and that the locks and tags should not be removed
until all persons have left the confined space.
(v) Where more than one person is in the confined space, the isolating device should be
either -
(1) locked or tagged, or both, by each person entering the confined space, or
(2) locked or tagged, or both, by a competent person authorised in writing by the employer.
(vi) Where the locking or tagging is undertaken by a competent person authorised in writing
by the employer, all persons entering the confined space should verify, or have it verified to
them, that isolation is effective prior to their entry.
(g) Removal of means of isolation
The locks, tags, blanks or other protective systems should only be removed after the
competent person, authorised in writing by the employer, ensures that work has been
suspended or completed and all persons have vacated the confined space.
(h) Cleaning prior to entry
Where practicable, all substances, which are likely to present a hazard to persons who enter
the confined space, should be removed prior to any entry to the confined space.
(i) Need for entry Where practicable, a confined space should be cleaned without entry.
Where entry is necessary for the purposes of cleaning, an entry permit is required.
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(j) Location of contaminants Potentially hazardous levels of contaminants may be trapped

in sludge, scale or other deposits, brickwork or behind loose linings, in liquid traps, or in
instrument fittings, and may be released only when, for example, it is disturbed or heat is
applied. Similarly, such material may lodge in joints in vessels or in bends of connecting
pipes or other places where removal is difficult.
(k) The employer shall ensure that, where appropriate, the confined space shall be cleared of
contaminants by use of a suitable purging agent. An employer shall ensure that pure oxygen
or gas mixtures with oxygen in a concentration greater than 21 percent by volume is not used
for purging or ventilation.
(l) Exhaust location The methods employed should ensure that any contaminants removed
from the confined space are exhausted to a location where they present no hazard.
(m) Ventilation :-Ventilation of a confined space should be by natural, forced or mechanical

means to establish and maintain a safe breathing atmosphere. This ventilation should be
continued throughout the period of occupancy.
(n) Exhaust location Exhaust facilities should be arranged to ensure that any contaminated
air removed from the confined space does not present a hazard to persons or equipment.
Combustion engines providing power for compressed air or any other use associated with the
work being done in the confined space should be located so that their exhaust emissions
cannot enter within the confined space or contaminate air being supplied to the confined
space.
(o) Ventilating with oxygen Pure oxygen or gas mixtures with oxygen in concentration
greater than 21 percent by volume shall not be used to ventilate a confined space.
SAFETY OF THE ATMOSPHERE
(a) The employer shall ensure that no person enters a confined space without an entry permit.
(b) The employer shall ensure, before a person enters a confined space, that where
practicable:
(i) the confined space contains a safe oxygen level (19.5% to23.5%);
(ii) the concentration of flammable contaminant and vapour is < 5% of LEL ;
(iii) potential toxic contaminants are < 50% of the AEL;
(iv) the confined space is free from extremes of temperature; and shall ensure
(v) the atmospheric contaminants in the confined space are reduced to below the relevant
exposure standards
(c) The employer shall ensure that atmospheric testing and monitoring is carried out
consistent with the hazards identified and the risk assessment.
55
(d) Periodic monitoring needs to be at least every 2 hours.
(e)Continuous Monitoring
(i) When activity inside the space or outside the space has the direct potential to alter the
atmospheric conditions
(ii) Keep monitor close to work and where attendant is swiftly aware of its alarm
(iii) Visually check readings when possible; do not rely on alarms only
(f) The employer shall ensure that where it is not practicable to provide a safe oxygen level,
or atmospheric contaminants cannot be reduced to safe levels, no person enters the confined
space unless they are equipped with suitable personal protective equipment including air
supplied respiratory protective equipment.
(g) Exposure standards. Compliance with an exposure standard is mandatory where a

relevant standard has been incorporated into legislation. Where there is no exposure standard,
professional advice should be obtained.
(h) Atmospheric evaluation an evaluation of the atmosphere and a survey of other hazards
should be performed from outside the confined space before any entry occurs. The results
should be recorded on the entry permit. It is intended that entry into, or work in a confined
space, the atmosphere of which has been established and maintained as being acceptable for
entry, be still in compliance with the requirements of this Standard.
(i) Test required The evaluation of the atmosphere should include testing by scientific
means for –
(a) oxygen content;
(b) airborne concentration of flammable contaminants; and
(c) airborne concentration of potentially harmful contaminants, unless suitable personal

protective equipment including air supplied respiratory protective equipment is worn during
entry and occupation of the confined space.
(j) Gas detectorsThe continuous-monitoring flammable gas detector should be fitted with
latching, visible and audible alarms which should activate at a contaminant concentration
above the acceptable level.
RISK CONTROL:
(a) Subject to review of the risk assessment completed in accordance, the employer shall
provide written approval, in the form of an entry permit, prior to work in a confined space
being carried out.
56
(b) The employer shall ensure that no person enters a confined space without an entry permit
and that:
(i) the entry permit includes any precautions or instructions necessary for safe entry and
execution of the work
(ii) the entry permit is provided to the person responsible for the direct control of the work in
a confined space, and records which persons enter the confined space; and
(iii) the persons involved in the work are advised of, understand and comply with the contents
of the entry permit.
(c) An employer shall ensure and acknowledge, in writing, that work in the confined space
has been completed and that all persons involved in the work have left the space before
authorization for the return to service of the confined space is made.
(d) Issue of entry permit The entry permit should state the period of its validity and should be
revalidated whenever it becomes evident that the duration of work will involve one of the
following:
(i) A change in the person responsible for the direct control of the work in a confined space.
(ii) A significant break in work continuity.
(iii) A significant change in atmosphere or work to be performed.
(e) Display of entry permit:-The entry permit should be displayed in a prominent place to
facilitate signing and clearance. A copy should be held by the employer.
(f) Recording persons entering a confined space:-The name of each person entering a
confined space and each person required for stand-by purposes should be recorded.
(g) Completion of entry permit:-The employer should be responsible for ensuring that the
entry permit is completed.
(h) The employer shall ensure that where the risk assessment indicates a risk to health and
safety, no person enters a confined space unless stand-by person(s) are present outside the
confined space.
(i) Provision of stand-by person :- The employer should provide stand-by person(s)
wherever the risk assessment indicates that -
(i) there may not be a safe oxygen level;
(ii) atmospheric contaminants are present or may be present in concentrations above the
exposure standards;
(iii) there may be a risk of fire or explosion;
(iv) there may be a risk of entrapment or engulfment;
57
(v) the work to be performed may generate risk to health or safety;
(vi) equipment or conditions outside the confined space require control or monitoring to
ensure the health and safety of persons in the confined space (for example, ventilation,
respirator air supply, vehicles and weather);
or
(vi) there may be other risks to the health or safety of persons entering the confined space.
(j) Communication :- Employers should ensure that communication and, where practicable,
observation between those in the confined space and the stand-by person(s) are capable of
being constantly maintained. Communication can be achieved, dependent on the conditions
existing in the confined space, in a number of ways, including voice, radio, hand signals and
other appropriate means.
(k) The employer, prior to any person entering a confined space, and during any occupancy
of the confined space, shall ensure appropriate signs and protective barriers are erected to
prevent entry of people not involved in the work.
(l) An employer shall provide suitable equipment, including, where necessary, equipment for:
(i) personal protection;
(ii) rescue;
(iii) first aid; and
(iv) fire suppression.
(m) The employer shall ensure that the equipment is appropriate to the work to be carried out
in the confined space, and maintained in a proper working condition. The employer shall
ensure that personal protective equipment and rescue equipment is selected and fitted to suit
the individual.
(n) Respiratory protective devices :- Suitable supplied-air respiratory protective devices

should be worn where -
(i) the results of the assessment or monitoring indicate that a safe atmosphere cannot be
established or may not be maintained; or,
(ii) the nature of the work procedure within the confined space is likely to degrade or
contaminate the atmosphere in the confined space (for example, hot work, painting or
removal of sludge).
(o) Safety harnesses and lines :- Suitable safety harnesses and safety lines or rescue lines
(i) there is a hazard of falling during ascent or descent; or
(ii) rescue by a direct route, either vertical or horizontal, is practicable.
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(p) Precautions for use :- It is not always desirable to specify the use of a safety harness,
safety line or rescue line as this may be impracticable. When considering specifying the
wearing of such equipment, care should be exercised to ensure that such equipment would
not introduce a hazard or unnecessarily hinder free movement within a confined space. In the
event of free movement being hindered, alternative plans should be arranged, for example,
for rescue and fall arrest.
(q) Rescue considerations :- Removal of unconscious persons from confined spaces is

extremely difficult. The use of hand-operated lifting equipment should be considered and,
where appropriate, be on site before entry to the confined space is permitted.
(r) Ignition sources:-Where a flammable atmosphere is likely to exist, precautions should be

taken to eliminate all sources of ignition.
(s) Gas cylinders :- Where practicable, no cylinder of compressed or liquefied gas, other
than those used for self-contained breathing apparatus, should be taken into a confined space.
The compressed or liquefied gas supply to equipment in the confined space should be turned
off at the cylinder valve when not in use. These gas cylinders should be secured. Hoses
supplying gas -operated equipment used in a confined space should be located, suspended or
otherwise guarded to avoid accidental damage. In addition, these hoses should be tested for
leaks prior to installation.
(t) Portable ladders:-Where a portable ladder is used, particular care should be taken to
ensure it is firmly secured to prevent movement.
(u) No portable electric light or any other electric appliance of voltage more than 24 Volts
shall be permitted for use inside any confined space.
RESCUE AND FIRST AID
(a) General The need for the rescue of personnel from a confined space and the provision of
first aid,
either in the confined space or after rescue from the space, may arise. This may include the
involvement of the emergency services. The employer shall ensure that appropriate rescue
and first aid procedures and provisions are planned, established and rehearsed. Also, the
confined space rescue team members must be specially trained and only these trained persons
shall be allowed to carry out the rescue operation.
(b) Procedures All persons who may be involved in any way with rescues from a confined
space should be made aware that -
(i) well-planned and well-rehearsed rescue procedures are essential and are to be followed at
all times; and
(ii) in an emergency, the spontaneous reaction to immediately enter and attempt a rescue
from a confined space may lead to the deaths or serious injury of those attempting the rescue.
(c) An employer shall ensure that:
59
(i) openings for entry and exit to a confined space are of adequate size to permit rescue of all
persons who may enter a confined space; and
(ii) the openings are not obstructed by fittings or equipment which could impede rescue, or,
where this is not practicable, that a suitable alternative means of rescue is provided.
(d) MEANS OF ENTRY AND EXIT
Except for boilers and pressure vessels, each confined space should be provided with at least:
(i) one entry having an aperture not less than 450 mm long by 400 mm wide, if rectangular,
or not less than 450 mm in diameter, if circular, or having major and minor axes not less than
450 mm and 400 mm respectively, if elliptical; or
(ii) other suitable means of entry and exit meeting the intent of Item (a).
450 mm
450 mm 4
450 mm
0
400mm 0
mm
m
TYPICAL CHECKLIST: m
The following checklist provides a ready reference of the major considerations that apply to
work in a confined space. This list, or an alternative list designed for a particular confined
space or industry, should be used in order to minimize the risks involved in confined space
work.
(1) PRE-ENTRY The pre-entry considerations should be at least as follows:
(a) Employee selection, including evaluation of an employee’s aptitude and fitness for task
and confined space entry.
(b) Employee training should include at least the following:
(i) Emergency entry and exit procedures.
(ii) Use of applicable respiratory protective devices.
(iii) First aid including cardio-pulmonary resuscitation (CPR).
(iv) Lockout procedures.
(v) Safety equipment use.
(vi) Rescue drills.
(vii) Fire protection.
60
(viii) Communications.
(c) Actions required are as follows
(i) Coordinate planning of work.
(ii) Coordinate supervising of work.
(iii) Implement emergency rescue plan.
(iv) Initiate safe work practices.
(v) Signpost work area.
(vi) Isolate confined space.
(vii) Evaluate confined space environment.
(viii) Comparison of initial test results with existing standards to determine ventilation and/or
personal protection requirements.
(ix) Ventilate and/or provide personal protection.
(x) Provide for monitoring of confined space during work.
(xi) Ensure that standby staff are available for rescue and operation of essential equipment.
(xii) Ensure rescue equipment is readily available and in order.
(xiii) Authorize entry by permit.
(xiv) Suspend work/evacuate space if conditions change to present real/potential danger.
(d) Recognition of potential hazards. The hazards to be considered should include at least
the following:
(A) Physical agents:
(i) Thermal extremes.
(ii) Radiation.
(iii) Noise.
(iv) Flooding.
(B) Chemical agents:
(i) Combustible gases or vapours.
(ii) Toxic gases or vapours.
(iii) Combustible or toxic liquids or solids.
61
(iv) Potentially explosive dusts.
(C) Oxygen deficiency or excess
(D) Potential hazards during work
(2)DURING ENTRY AND RE-ENTRY
The considerations during entry and re-entry should be at least the following:
(a) A comparison of initial test results with an existing standard to determine whether
ventilation or personal protective equipment will be used.
(b) Continuous or periodic monitoring of confined space atmosphere.
(c) Ensure safe work practices followed.
(d) Reissue permit after absence from area or if conditions change.
62
63
CONFINED SPACE ENTRY PERMIT
Sl. No………………………. Dated………………………
PART – I : TO BE FILLED / AUTHENTICATED BY COMPETENT PERSON
A. Departmental Information
1. Requested by Chief/HOD of the Department on
Date……………………………………………………………
2.Name of the
Department……………………………………………………………………………………
………
3. Actual Location of Confined

Space…………………………………………………………………………………
Method of Isolation: From Gas System and all other Piped Utility Services
1.
Gas………………………………………………………………………………………
……………………………..
64
2. N2/Inert
Gas………………………………………………………………………………………………
…………...
3. Steam………………………………………………….
Water……………………………………………………….
4. Any Other
Lines……………………………………………………………………………………………
………….
Results of test and Observations
Oxygen……………………………………..% Aromatic
Hydrocarbon………………………………….PPM
CO………………………………………….PPM
Dust……………………………………………….………PPM
NH3………………………………………...PPM Any other

Fumes………………………………………..PPM
TEST HAVE BEEN CARRIED OUT IN THE ABOVE MENTIONED CONFINED SPACE
AND ENTRY IS PERMITTED AS INDICATED BELOW;
Recommendation for Periodic

Checking……………………………………………………………………………..
D) Entry Without Breathing Apparatus
Clearance for Entry Without Breathing Apparatus is valid-
From Date…………………………………
Time…………………………………..
Until Date………………………………….
Time…………………………………..
E) Entry Wearing Breathing Apparatus
Entry wearing Breathing Apparatus subject to the following conditions-
65
1. An observer must be positioned outside the confined space.

2. Where practicable, each man is wearing belt or harness with life line attached
and that the observer positioned outside is holding the free end of the life line
and is capable of pulling out the men.
Valid From Date…………………………….
Time………………………………
Until Date……………………………..
Time………………………………
F) Any Other Observations
…………………………………………………………………………………………
………………………………….
…………………………………………………………………………………………
………………………………….
Person Carrying out the test Name……………………………….

Signed…………………….
Competent Person Name……………………………….

Person accepting the Certificate Name……………………………….

THIS CERTIFICATE IS NOT A PERMIT TO WORK
A SEPARATE PERMIT TO WORK CERTIFICATE MUST BE OBTAINED WHERE

APPLICABLE.
PERMIT FOR WORKING IN CONFINED SPACE

PART-II : TO BE ISSUED BY DEPARTMENTAL REPRESENTATIVE
Department …………………………………………………
Ref.: Work Permit
No. :………………….. 66
Date : …………………
Confined space to be entered …………………………………………………
Work to be performed …………………………………………………
Possible Hazards …………………………………………………
Person Responsible …………………………………………………
CHECKLIST
Yes No N/A
Pumps/lines disconnected/blanked/de-energized …….. ……

……..
Confined space Purged/Flushed …….. …….. ……..
Ventilation provided
Forced …….. …….. ……..
Natural …….. …….. ……..
Direct reading gas monitors tested/calibrated …….. …….. ……..
Safety harness and lifelines for entry and standby persons available …….. ……..
……..
Adequate personal protective equipment provided …….. …….. ……..
Explosion proof 24V electric equipment (class1, division1, groupD) ……..……..

……..
Non-Sparking tools available …….. …….. ……..
Breathing Apparatus required to be put on …….. ……..

……..
Breathing Apparatus available for emergency …….. ……..

……..
Fire Extinguishers/Fire Hydrant lines available …….. ……..

……..
All persons engaged for working provided required training …….. ……..
……..
67
Rescue training provided …….. ……..

……..
Communication Procedure (Communication between person inside the confined space and
outside)
…………………………………………………………………………………………
….
…………………………………………………………………………………………
….
Rescue Procedure
…………………………………………………………………………………………
….
…………………………………………………………………………………………
….
Atmospheric check after isolation and ventilation (Measured by a calibrated equipment)
Oxygen…………………………………>19.5%
CO……………………………………..<50ppm
NH3…………………………………….<15ppm Aromatic
Hydrocarbon………………<5ppm
Flammable gas/vapour………………<10%LEL
Dust……………………………………
Any Other Fumes…………………….
(Date……………………… Time…………………… Testers

Signature………………………….)
68
Periodic monitoring is necessary if work itself generates toxic or flammable vapor or when
there is a possibility that such vapor will enter the space. If work ceases for any reason, the
atmospheric testing should be repeated before entry.
Periodic Atmospheric check
……………………………….
Time………………………..Date………………………
………………………………. (Use separate sheet if more

readings are required)
……………………………….
We have reviewed the work authorized by this permit and safety procedures are understood.
This permit to be issued only after getting certification from competent person for entry in
confined space
Permit issued by Dept. Representative Permit Received by Working Agency
(Signature with Date & Time)…………….. (Signature Date &

Time)………………………….
Name …………………………., Desig………………

Name………………………………..,Desig……….
RETURN OF ‘PERMIT TO WORK’ AFTER JOB COMPLETION
Permit returned by Working Agency Permit Received Dept. Representative
(Signature with Date & Time)…………….. (Signature Date &

Time)………………………….
Name …………………………., Desig………………

Name……………………………….., Desig ………………
(A) Confined Space Identification Form
69
Area: Confined Space (Yes/No) _____________
Must meet “all” three of the following criteria to be deemed a “Confined Space!” Yes/No?
_______ Is large enough and configured such that an employee can bodily enter and perform
assigned work,
-AND-
________ Has limited or restricted means for entry or exit,
-AND-
________ Is not designed for continuous employee occupancy.
If you answered “yes” to “all” three of the above then the area is deemed a “CONFINED
SPACE!”
You must meet all three of the above criteria and one or more of the following to be deemed
a “CONFINED SPACE!”Yes/No?
________ Contains or has a potential to contain a hazardous atmosphere?
-AND/OR-
________ Contains a material that has the potential for engulfing and entrant?
-AND/OR-
________ Has an internal configuration such that an entrant could be trapped or asphyxiated
by inwardly covering walls or by a floor, which slopes downward and tapers to a smaller
cross section?
-AND/OR-
________ Contains any other recognized serious safety or health hazard?
If you answered “yes” to “all” three of the first criteria and “yes” to one or more of the
rest of the criteria then it is a “CONFINED SPACE!”
Some examples include: tanks, tank cars, vessels, vessel skirts, hoppers, open vessels,
trenches or pits, diked areas, vaults, pipe lines, tunnels, ductwork, boilers and manholes
INSPECTED BY _____________________________________
DATE ______________________________________________
70
PERMIT TO WORK (PTW)
Permit to work:-The permit-to-work is a documented procedure that authorises certain

people to carry out specific work within a specified time frame. It sets out the precautions
required to complete the work safely, based on a risk assessment. It describes what work will
be done and how it will be done; the latter can be detailed in a ‘method statement'.
The permit-to-work requires declarations from the people authorising the work and carrying
out the work. Where necessary it requires a declaration from those involved in shift handover
procedures or extensions to the work. Finally, before equipment or machinery is put back into
service, it will require a declaration from the permit originator that it is ready for normal use.
Types of permit to work:-
 Working at height
 Gas cutting welding
 Cleaning
 Painting
 Hydraulic System
 Rigging & Fitting
 Confined Space etc.
Procedure:-
1) The owner department will isolate the equipment to ensure “It is Safe” to work prior
to issue of any work permit. The isolation will be as per written procedure which is
attached to the work permit. A written isolation procedure is required for every job
(Which requires isolation).
2) Supervisor (Permit requested by) of the group performing the work will make the
necessary contact with the owner supervisor (Permit Issued by) concerning the job.
Supervisor (Permit taken by) of the group who will carry out the work will be
responsible for “Permit taken by”. If the job is carried out by the Contractor under
Central Agency, Central agency will countersign, and will be responsible for Safe
execution of the job.
3) Prior to start the work, the work permit will be filled up in duplicate to clarify the
type of work involved, precautions taken, etc. Supervisor of the group (permit
requested by) performing the job will be responsible for filling out the form. Owner
supervisor (Permit Issued by) will be responsible for explaining the proximity hazards
of the area and necessary precautions. Supervisor (Permit taken by) of the group doing
the job will be responsible for carry out the job safely including proximity hazards,
PPEs of their employees, proper tools & tackles.
4) Before the permit is issued, the issuer will ensure that all precautions in co-
ordination with other agencies/ running equipments / other activities are taken into
consideration. Before the permit is issued, executing agency will ensure that all
precautions indicated in the permit format are being considered. The original copy of
the signed permit is then given to the supervisor of the group responsible for doing the
job.
Guidelines:
71
1) Safe Work Procedure should be made in advance, in the prescribed format

EHSMSM / WORKS / 446 / 4009. It should contain hazards involved and precautions
of the job to be performed including proximity hazards.
2) It should contain safety measures as indicated in safety standards, local rules &
procedure (By dept.) and statutory requirements. Contractor working under Central
agency -SWP should be made by Central agency in consultation with departmental
agency.
3) Training of Safe Work Procedure should be provided to all Contractors’ Supervisor
by department regarding hazard involved during the job and its precautions.
4) Associated hazards and necessary precaution of the job being carried out, will be
imparted to all contractor workers by Contractor’s Supervisor. Department should
ensure that permit should be given only after verifying the Contract workers are well
aware of Safe Work Procedure.
5) Job should be carried out after getting Permit to Work System. It should be filled up
after anticipating the proximity hazard. Self certification by contractor should be taken
for all tools & PPEs etc.
6) Permit to work format is valid for only one area.
7) For confined space work: To work in confined space “permit to work” format
should be issued against departmental confined space permit number (EHSMSM /
WORKS / 446 / 4002). Departmental confined space number should be generated
against Confined space clearance (EHSMSM / WORKS / 446 / 4002) taken from
Competent person.
The list of competent persons for Confined space:

A person declared by Chief Inspector of Factories as competent under Section 36 of
Factory Act 1948 based on qualification, experience and facilities available at his
disposal to certify a confined space as safe to work based on test / examination of
atmosphere carried out by himself
8) Permit to work Format:
Permit requested by – Permit will be requested by the departmental agency

under which job will be carried out.
Permit Issued by: Permit will be issued by Owner of the area / equipment.
Permit taken by: Permit will be taken by the agency that will perform the job.
9) Permit to be signed by not less than Supervisor / Shift In-charge / Dept. authorized
person.
10) Audit should be conducted before and during the job to evaluate the severity
level.
72
73
Back page
INSTRUCTIONS
1. Permit to be signed by Shift Incharge/ Person Incharge of the Job/ Supervisor/ Officer/
Sr. Associate/ Any other person authorised by Head/Chief of the Department.
2. If the job is being done under Central Working Agency like MSG/ Engg. Services etc,
permit to work will be given by them only, where as the clearance to Central agency to be
given by the departmnet
3. Contractor should provide one Site Safety Supervisor for 30 contract
employee.
4. Proximity/ 6 direction hazards should be assessed by Executing Agency before starting of
job and communicate to working Agency.
(To be filled by Working Agency)
Checked by Working Agency(Use √ or × as Check Points
appropriate & NA for not applicable)
1. Safe Operating procedure has been made and approved in form
#EHSMSM/WORKS/446/4009.
2. Welder cum Gas Cutter and Rigger (at least height test) must have trade test pass
certificate from ITI or any institute which is certified by SNTI/ Safety Department, Tata
Steel.
3. All persons are Certified medically fit.
4. All lifting tools and tackles are in good condition with valid test certificate.
Sl. No. Gate Incoming outgoing Safety 1st 2nd Name
Pass No. time time induction renewal renewal
(Date & (Yes / (Yes /
Time) No) No)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
74
17
18
19
20
75
EXCAVATION
What is Excavation?
OSHA defines an excavation as any man-made cut, cavity, trench, or depression in the earth's
surface formed by earth removal. This can include excavations for anything from cellars to
highways.
What is Trench?
A trench is defined as a narrow underground excavation that is deeper than it is wide, and no
wider than 15 feet (4.5 meters).
Associated Hazards:-
• Falling of persons into excavation;

• Collapse of excavation sides and falling of excavated material onto persons working
within excavation.
• Collapse of temporary structure made to support sides of excavation.
• Collapse of adjacent building or structure due to excavation.
• Persons within excavation struck by parts of machine, falls of spoil from excavator
buckets and other objects dropped on them.
• Striking underground electric cables with resulting flash burns and electric shock.
• Striking and breaking other underground service lines – gas (fire and explosive
hazard), water (flooding), and sewage (toxic gases).
• Fire and explosion from flammable gases heavier than air and vapors especially LPG,
entering excavation.
• Poisoning from gases heavier than air such as hydrogen sulphide or carbon dioxide
present in ground itself, or entering the excavation from outside.
• Poisoning from carbon monoxide produced from torches, burns, etc. used in
excavation with insufficient ventilation, or from exhaust gases produced by plants and
machinery used in connection with the excavation, including pumps for dewatering.
• Toxic and radioactive hazards from the ground itself, usually resulting from its
previous occupancy.
• Flooding with risk of drowning.
• Accidental explosion through use of explosive in excavation.
• Falling of workmen through bottom of excavation into disused mine shaft or other
cavities in the ground.
Definitions :
(a) Bell-bottom Pier Hole – A type of shaft or footing excavation in which the bottom is
made larger than the cross section above to form a belled shape
76
(b) “Benching (benching system) A method of protecting employees from cave-ins by

excavating the sides of an excavation to form one or a series of horizontal levels or steps,
usually with vertical or near-vertical surfaces between levels.
(c) “Cave-in” The separation of a mass of soil or rock material from the side of an
excavation, or loss of soil from under a trench shield or support system, and its sudden
movement into the excavation in quantity that it could entrap, bury, injure, or immobilize a
person.
(d) “Competent person” One who can identify existing or predictable hazards in the
surroundings that is unsanitary, hazardous, or dangerous to employees. Also has authorization
or authority by the nature of their position to take prompt corrective measures to eliminate
them. The person shall be knowledgeable about the requirements of this part.
(e) Concrete Breaking – Work performed with hand tools such as jackhammers or
mechanical equipment to break or chip concrete floors or walls. This work requires an
excavation permit.
(h) “Cross braces” The horizontal members of a shoring system installed perpendicular to
the sides of the excavation, the ends of which bear against either uprights or walls.
(l) “Protective system” A method of protecting employees from cave-ins, from material that
could fall or roll from an excavation face or into an excavation, or from the collapse of
adjacent structures. Protective systems include support systems, sloping and benching
systems, shield systems, and other systems that provide the necessary protection.
(m) “Ramp” An inclined walking or working surface that is used to gain access to one point
to another, and is constructed from earth or from structural materials such as steel or wood.
(o) “Shield (shield system)” A structure that is able to withstand the forces imposed on it by
a cave-in and thereby protects employees within the structure. Shields can be permanent
structures or can be designed to be portable and moved along as work progresses.
(p) “Shoring (shoring system)” A structure such as a hydraulic, mechanical, or timber

shoring system that supports the sides of an excavation and which is designed to prevent
cave-ins.
(q) “Sloping (sloping system)” A method of protecting employees from cave-ins by

excavating to form sides of an excavation that are inclined away from the excavation so as to
prevent cave-ins. The angle of inclination required to prevent a cave-in varies with
differences in such factors as the soil type, environmental conditions of exposure, and
application of surcharge loads.
u) “Trench (trench excavation)” A narrow excavation in relation to its length made below
the surface of the ground. In general, the depth is greater than the width, but the width of a
trench (measured at the bottom) is not greater than 15 feet (4.6m).
(B) General Protection Requirements.
77
Many excavation accidents are the direct result of inadequate initial planning. The
construction engineeris responsible for planning the job. He or she must involve the site’s
competent person in planning and inall phases of the work. Every effort should be made
during the design stage of the excavation to ensuresafety by providing the necessary
protective systems. The construction engineer at each site should be aware of specific
requirements in that site’s jurisdiction.
(1) Planning
Site Conditions – Before an excavation begins, the construction engineer must consider
specific site conditions such as the following:
– presence of a competent person
– traffic
– vibrations in the vicinity of the worksite
– proximity of structures and their conditions
– soil
– surface water and groundwater
– chemical contamination of soil or water
– water table
– overhead and underground utilities
– weather
If desired, the construction engineer can use the attached sample safety checklist (see
Attachment) to help plan excavation safety.
(2) Minimum Precautions – Before beginning an excavation, the construction engineer or

designee must take the following additional minimal precautions:
– Provide warning vests for employees exposed to vehicular traffic.
– Erect either warning barricades or rigid, protective barricades to avoid leaving an

excavation hazard
unprotected. If warning barricades are used, place them a minimum of 5 feet (1.5 meters)
from the excavation edge. A spoil pile at least 3 feet (1 meter) high can be used as a barricade
on one side of the excavation. Barricades must be marked with warning lights if they are in or
near walkways or roadways.
78
– Provide warning systems such as barricades, hand or mechanical signals, or stop logs to
alert operators of mobile equipment that they are approaching the edge of excavations.
– Keep spoil dirt and any material or equipment that may fall into an excavation at least 3 feet
(1 meter)
from the edge.
(3) Surface encumbrances: All surface encumbrances that are located so as to create a
hazard to employees shall be removed or supported, as necessary, to safeguard employees.
(4) Underground installations.
(a) The location of utility installations, such as sewer, telephone, fuel, electric, water lines, or
any other underground installations that reasonably may be expected to be encountered
during excavation work, shall be located prior to opening an excavation. Supervisor shall
obtain excavation clearance from E&P division (or other concerned department, i.e. Civil
Engineering, Electrical Department, Design Department) before start of the work so as to
prevent the hazards due to the underground structures.(Refer attached Annexure for Format
of Excavation Clearance). After obtaining the excavation clearance, the excavation area is
examined by cable detector to identify the underground cables then trial trench excavation
shall be undertaken manually only. The depth of trial trench shall not exceed 1.5 meters in
general 2.0 meter in special cases so as to ascertain the presence of any cable/gas
pipeline/other utility. In case, no cable or other utility service lines detected in the trial trench,
mechanical excavation upto 1.2 m depth shall be undertaken. Then again cable detector is
used to check the underground cables at this stage .If no signals are found then mechanical
excavation can be undertaken upto the desired depth. for further depth.
(b) While the excavation is open, underground installations shall be protected, supported, or
removed as necessary to safeguard employees.
(c)Necessary precautions for confined space shall be taken into consideration while working
in excavation.
(5) Access and Escape :
(a) It is recommended that one ladder should be provided for every length of 15 m or fraction
thereof, in the case of hazardous work, and 30 m of length or fraction thereof, in the case of
relatively less hazardous work.
(b) Ladder shall extend at least 1 meter top of the cut to provide a hand hold when stepping
on or off.
(c) Quite often the pathways become slippery due to accumulation of mud, sand or gravel.
This should be avoided. Further, the pathway should be strong enough to withstand the
intended use. Similarly gangway should be of superior construction.
79
(d) The planks used should be strong and parallel to the length of the gangway and fastened
together against displacement. They should be thick and have cleats for sate walking.
Gangways /Pathway/ Walk way should be kept clear of excavated material and other
obstruction.
(6) Exposure to falling loads:
No employee shall be permitted underneath loads handled by lifting or digging equipment.

Employees shall be required to stand away from any vehicle being loaded or unloaded to
avoid being struck by any spillage or falling materials. Operators may remain in the cabs of
vehicles being loaded or unloaded when the vehicles are equipped.
(7) Hazardous atmospheres:
(a) In case of presence of harmful gas, adequate arrangements for ventilation shall be
provided to restrict the exposure within safe limits. Such tests shall be carried out frequently.
(b) Explosive mixed gases may also be present in the trenches, air containing more than 1.5
percent of flammable gases by volume is dangerous.
(c) Air shall be considered unfit for workmen to breath, if it contains any of the following:
(i) Less than 19 percent of oxygen by volume.
(ii) More than 1 percent of carbon dioxide by volume.
iii) More than 0.01 percent of carbon monoxide by volume.
(iv) More than 0.0025 percent of hydrogen sulphide gas by volume and
(v) More than 0.002 percent of nitrous oxide by volumes.
(d) No internal combustion engine should be operated in a trench unless adequate ventilation
measures are taken for discharge of exhaust gases.
(e) Dusty Atmosphere :When the excavation activity causes dust generation which can be
harmful to the employees ,necessary action must be taken to suppress it (e.g. spraying water)
or employees must wear proper PPE while working in such atmosphere.
(f) Excavations as Confined space: If the competent persons feels that the excavation has
the hazards of confined space then all the necessary precautions must taken which are
applicable while working in confined space. For this refer the standard of Working in
Confined Space
(f) Emergency rescue :
80
(i)The supervisor or foreman shall make the employees aware about the location of the First
Aid box/Competent First Aiders/OHS Centre.
(ii) Emergency rescue equipment, such as breathing apparatus, a safety harness and line, or a
basket stretcher, shall be readily available where hazardous atmospheric conditions exist or
may reasonably be expected to develop during work in an excavation. This equipment shall
be attended when in use.
(8) Protection from hazards associated with water accumulation:
(a) Employees shall not work in excavations in which there is accumulated water, or in
excavations in which water is accumulating, unless adequate precautions have been taken to
protect employees against the hazards posed by water accumulation. The precautions
necessary to protect employees adequately vary with each situation, but could include special
support or shield systems to protect from cave-ins, water removal to control the level of
accumulating water, or use of a safety harness and lifeline.
(b) If water is controlled or prevented from accumulating by the use of water removal
equipment, the water removal equipment and operations shall be monitored by a competent
person to ensure proper operation.
(c) If excavation work interrupts the natural drainage of surface water (such as streams),
diversion ditches, dikes, or other suitable means shall be used to prevent surface water from
entering the excavation and to provide adequate drainage of the area adjacent to the
excavation. Excavations subject to runoff from heavy rains will require an inspection by a
competent person.
(9) Stability of adjacent structures:
(a) Where the stability of adjoining buildings, walls, or other structures is endangered by
excavation operations, support systems such as shoring, bracing, or underpinning shall be
provided to ensure the stability of such structures for the protection of employees.
(b) Excavation below the level of the base or footing of any foundation or retaining wall that
could be reasonably expected to pose a hazard to employees shall not be permitted without
approval of site in charge
(c) Sidewalks, pavements, and appurtenant structure shall not be undermined unless a support
system or another method of protection is provided to protect employees from the possible
collapse of such structures.
(10)Protection of employees from loose rock or soil:
(a) Adequate protection shall be provided to protect employees from loose rock or soil that
could pose a hazard by falling or rolling from an excavation face. Such protection shall
consist of scaling to remove loose material; installation of protective barricades at intervals as
necessary on the face to stop and contain falling material; or other means that provide
equivalent protection.
81
(11) Inspections:
(a) Daily inspections of excavations, the adjacent areas, and protective systems shall be made
by a competent person for evidence of a situation that could result in possible cave-ins,
indications of failure of protective systems, hazardous atmospheres, or other hazardous
conditions. An inspection shall be conducted by the competent person prior to the start of
work and as needed throughout the shift. Inspections shall also be made after every rainstorm
or other hazard increasing occurrence. These inspections are only required when employee
exposure can be reasonably anticipated.
(b) Where the competent person finds evidence of a situation that could result in a possible
cave-in, indications of failure of protective systems, hazardous atmospheres, or other
hazardous conditions, exposed employees shall be removed from the hazardous area until the
necessary precautions have been taken to ensure their safety.
(12) Fall protection:
(a) Walkways shall be provided where employees or equipment are required or permitted to
cross over excavations. Adequate barrier physical protection shall be provided at all remotely
located excavations. All wells, pits, shafts, etc., shall be barricaded or covered. Upon
completion of exploration and similar operations, temporary wells, pits, shafts, etc., shall be
backfilled.
(13) Cathodic Protection Systems
These systems are used to prevent corrosion of certain underground piping. Special cathodes
and/or anodes are used to circumvent corrosive damage to the pipeline by use of electrical
currents. If these systems are in the vicinity of an excavation, they must be de energized.
(C) Requirements for protective systems:
(1) The worker shall be provided proper briefing about the Cave-in and other Hazards before
proceeding to work by supervisor/foreman.
(2) Safety helmet and Shoes shall be worn by all persons entering trench/ excavation site.
(3) Tools or materials such as wheel borrow, shovels, picks, tiles, cement, lumbar shall not be
kept close to the edges of the trench.
(4) Warning notices shall be displayed at the site. All excavations must be provided with
Guard rails or Metal Plank Guards. Follow the standard barrication method.
(5) Every accessible part of an excavation, pit or opening in the ground into which there is a
danger of falling of person, shall be suitably fenced with a barrier as shown in standard
barrication sketch.
(6) All trenches in soil more than 1.5 m deep shall be securely shored and timbered. In case
of extremely loose soil shoring may be required even for depth less than 1.5 m.
82
(7) All trenches in friable or unstable rock exceeding 2 m in depth shall be securely shored
and timbered.
(8) The above requirements do not apply in cases, where the sides of the trenches are sloped
to within 1.5 m of the bottom. The slope that is provided for such purposes shall be inspected
and certified as stable by the person in charge of work in all cases.
(9) In case of any doubt with respect to the safety of the work, the requirement for providing
shoring shall be carefully considered, even in trenches less than 1.5 meter or 2 meter in depth
and decision taken accordingly.
(10) Where the sides of trenches are sloped, as specified above but not to within 1.5 m of the
bottom, the vertical sides shall be shored and the shoring shall extend at least 30 cm above
the vertical sides of the excavations. Care to be taken to prevent material rolling down the
slope and falling into the part of the trench with vertical walls.
(11) Shoring and timbering shall be carried along with the opening of a trench but when
conditions permit, protection work, such as sheet piling may be done before the excavation
commences.
(12) Approved quality of Sal wood should be used for shoring and timbering a trench. Any
other material can also be used, but shall not have the strength less than the Sal wood.
Figure 1 - Cave-in Hazards (Illustrative Examples)
a) TENSION CRACKS. Tension cracks

usually form at a horizontal distance of
0.5 to 0.75 times the depth of the trench,
measured from the top of the vertical face
of the trench. See the accompanying
drawing for additional details.
b) SLIDING or sluffing may occur as a

result of tension cracks, as illustrated
below.
c) TOPPLING. In addition to sliding,

tension cracks can cause toppling.
Toppling occurs when the trench's
vertical face shears along the tension
crack line and topples into the excavation.
83
d) SUBSIDENCE AND BULGING. An

unsupported excavation can create an
unbalanced stress in the soil, which, in
turn, causes subsidence at the surface and
bulging of the vertical face of the trench.
If uncorrected, this condition can cause
face failure and entrapment of workers in
the trench.
e) HEAVING OR SQUEEZING. Bottom

heaving or squeezing is caused by the
downward pressure created by the weight
of adjoining soil. This pressure causes a
bulge in the bottom of the cut, as
illustrated in the drawing above. Heaving
and squeezing can occur even when
shoring or shielding has been properly
installed.
f) BOILING is evidenced by an upward

water flow into the bottom of the cut. A
high water table is one of the causes of
boiling. Boiling produces a "quick"
condition in the bottom of the cut, and
can occur even when shoring or trench
boxes are used.
84
Shoring
Shoring
 As per IS specifications
 Based on manufacturer’s data
 Designed by Engineer
 Based on depth and width
 Based on soil type and condition
85
Simple Sloping
86
Worker must be made aware of :-
• Field personnel
• First Aid box
• Competent First Aider
• OHS centre / Hospital of
• Fire Department
RAILING
87
Mobile and suspended access equipment.
There will be many occasions when it will not be possible to work from an existing structure
and the use of a scaffold-based working platform would not be appropriate. A range of
mobile access equipment can be used, including:
 mobile elevated working platforms (MEWPs),

 mast platforms which are, in essence transportable lifts which are bought to the
required place of work.
 (cradles, bosun’s chairs or seats, rope access equipment which we will look at later)
It is essential that personnel who are going to use such equipment should be well-trained and
competent to operate it. They should also learn emergency and evacuation procedures so that
88
they know what to do, for example, if the power supply to the platform fails or fire breaks out
in the building where the work is taking place. This information should be given on a hand-
over certificate which will be provided by the supplier/installer. The certificate must also
provide all the relevant information about safe working loads and so on.
The safe system of work must ensure that:
 the area where the work is to be carried out is barriered off, or made secure to prevent
unauthorised entry;
 people cannot be struck by any moving parts as the platforms rise or descend;
 the platform is protected from damage, in particular by being struck by passing
vehicles;
 the access equipment is secure and capable of withstanding high winds if it needs to
be used outside.
It is probably worth saying a few specific words about MEWPs.
Place of work Timing and frequency of inspection

requiring Before After After any event At regular Before work at After
inspection being substantial likely to have intervals not the start of accidental
used for addition, affected its exceeding seven every shift. fall of rock,
the first dismantling or strength or days. earth or any
time. alteration. stability. material.
Any working
platform or part
thereof or any
✓ ✓ ✓ ✓
personal
suspension
equipment.
Excavations
which are
supported in
pursuit of ✓ ✓ ✓
paragraphs (1),
(2) or (3) of
regulation 12.
Cofferdams and
✓ ✓
caissons.
89
Checklist of typical scaffolding faults
Footings Standar Ledger Braci Couplin Bridles Ties Boardin Guar Ladders
ds s ng gs g d
Putlogs
rails
and
and
transo
toe
ms
board
s
Wron
Some Wrongl Some
Soft and Not Not Wrong Wrong Bad g Damage
missi y missi
uneven plumb level fitting spacing boards heigh d
ng spaced ng
t
No base Jointed Joints Loose Loose Loose Wrong Loose Trap Loose Insuffici
plates at same in same couplin boards ent
height bay gs length
Wron Wrongl No
Not Some
No sole Wrong g y Damag check Incompl
Loose enoug missi Not tied
plates spacing fitting support ed coupler ete
h ng
s ed s
No
Insuffici
Undermi Damage Damag check
ent
ned d ed coupler
supports
s
90
DEMOLITION
Associated Hazards:
Accidental Hazards
 Collapse of Structure
 Falling Material
 Flying Material
 Impact/Hit by Material
 Collapse of Equipment/Machinery
 Noise
 Entrapment
 Fall from height
 Electrocution
 Fire
 Explosion etc.
PREPLANNING & PRECAUTIONS BEFORE STARTING DEMOLITION WORK:
(1) Prior to permitting employees to start demolition operations, an engineering survey shall
be made, by a competent person, of the structure to determine structural integrity and the
possibility of unplanned collapse of any portion of the structure. Any adjacent structure
where employees may be exposed shall also be similarly checked. The employer shall have in
writing, evidence that such a survey has been performed.
(2) A definite plan of procedure for the demolition work shall be prepared by contractor and
finalized in consultation with E&P Division. A copy of the survey report and of the plans
and/or methods of operations shall be maintained at the job site for the duration of the
demolition operation.
(3) Contractor shall implement this plan in actual practice.
(4) Any device or equipment such as scaffolds, ladders, derricks, hoists, etc., used in
connection with demolition work shall be constructed, installed, inspected, maintained and
operated in accordance with the regulations governing the construction, installation,
inspection, maintenance and operation of such device or equipment. The cage, hoists, tackles
shall not be overloaded. Safety appliances (Helmet, Shoes, Goggles, Gloves, Safety Belts and
others as may be required) shall be used.
(5) Demolition of all buildings and structures shall be conducted under competent
supervision, and safe working conditions shall be afforded to the employees. Before the
commencement of each stage of demolition, the supervisor shall brief the workmen in detail
regarding the safety aspects to be kept in view.
91
(6) When employees are required to work within a structure to be demolished which has
been damaged by fire, flood, explosion, or other cause, the walls or floor shall be shored or
braced.
(7) All electric, gas, water, steam, sewer, and other service lines shall be shut off, capped, or
otherwise controlled, outside the building line before demolition work is started. In each case,
any utility service which is involved shall be notified in advance.
(8) All the mains and meters of the building shall be removed or protected from danger. If it
is necessary to maintain any power, water or other utilities during demolition, such lines shall
be temporarily relocated, as necessary, and protected.
(9) All the roads and open areas adjacent to the work site shall be protected and Caution
Boards/Danger Sign in local language, Hindi and English shall be displayed at prominent
places. Unauthorized entry to the building under demolition shall be efficiently controlled.
(10)Provisions shall be made for at least two independent exits for escape of workmen during
any emergency.
(11)During nights, red lights or luminescent danger sign shall be placed on or around all the
barricades.
(12)Following work permits shall be obtained by contractor from E&P Division.
(i) Power cutting clearance in approvedform and Power Clearance in form .

(ii) Work permit for Gas cutting and welding and working at height as may be applicable in
form EHSMSM/works/446/4001.
(iii)Work permit for working in gaseous areas in approved form if applicable.
(iv) Any other clearance as found appropriate by E&P Division in consultation with the
concerned department of Tata Steel.
(13)Walkways and passageways shall be provided for the use of the workmen and they will
be strictly instructed to use these only. All such walkways and passageways shall be kept
adequately lighted, free from debris and other materials.
(14)Shoring of other buildings/adjacent structures shall be provided when the demolition

operation exposes or breaches an adjoining wall of the adjacent structure.
(15)Before demolition buildings with over hangs, chajjas, etc. they should be properly
supported and demolished first before demolishing superstructure of the building.
(16)While breaking roof slabs, workmen shall not be allowed to sit on the same floor, but on
a separate platform, supported independently. In case they have to work from the same floor,
independent life line to fasten their lanyard shall be provided. Lifeline should not be
connected with the portion to be dismantled.
(17) It shall be determined whether asbestos, hazardous materials, hazardous chemicals,

gases, explosives, flammable materials, or similarly dangerous substances are present at the
work site. When the presence of any such substance is apparent or suspected, testing and
removal or purging shall be performed and the hazard eliminated before demolition is started.
92
(18) Protruding nails in boards, planks and timber shall be withdrawn, driven in or bent over
as soon as the same is removed from the structure being demolished.
(19) Any material to be removed which will cause dust to be formed, shall be sprinkled with
water to lay the dust incidental to its removal.
SEQUENCE OF DEMOLITION OPERATIONS:
Demolition is “Reverse construction”. This concept will help to form a general guideline
about sequence of demolition.
 Before demolition work is started, glazed sash, glazed doors and windows, etc. shall be
removed. All fragile and loose fixtures shall be removed. All loose plaster shall be
stripped off throughout the entire building.
 All exterior wall openings, which extend down to floor level shall be barricaded to a
height of not less than one meter above the floor level. This provision shall not apply to a
storey after structural demolition has been started for the ground level floor.
 All floor openings and shafts not used for material chutes shall be floored over and be
enclosed with guard rails and toe boards.
 The demolition shall always proceed systematically storey by storey in descending order
and the work on the upper floors shall be completely over before any of the supporting
members or other important portion on the lower floor is disturbed (These requirements
shall not prohibit the demolition of structure in sections., if means are taken to prevent
injuries to persons or damage to property).Stability of the remaining part of structure must
be checked, before dismantling of any part is taken up.
REMOVAL OF MATERIALS/DEBRIS
Debris shall not be allowed to be thrown from height. Remove all debris promptly, using
chutes or through internal holes.
93
Through Chutes
 Metal chutes may be provided for removal of materials. The chutes shall preferably be
provided at the centre of the building for efficient disposal of debris.
 Chutes, if provided at an angle of more than 45 degree from the horizontal shall be
entirely enclosed on all the four sides, except for opening at or about the floor level for
receiving the materials.
 Opening for the chutes shall not exceed 1.2 m in height measured along the wall of the
chute and in all storeys below the top floor such opening shall be kept closed when not in
use.
 To prevent the descending material attaining a dangerous speed, chute shall not be
extended in an unbroken line for more than two storeys. A gate or stop shall be provided
with suitable means for closing the bottom of each chute to stop the flow of materials.
 Chutes at an angle of less than 45 degree the horizontal may be left open on the upper
side provided that at the point where such a chute discharges into a chute steeper than 45
degree to the horizontal. The top of the steeper chute shall be boarded over to prevent the
escape of materials.
 Any opening into which workmen dump debris at the top of a chute shall be guarded by a
substantial guard rail extending at least one meter above the level of the floor or other
surface on which men stand to dump the material into the chute.
 A toe board or bumper not less than 50 mm thick and 150 mm high shall be provided at
each chute opening, if the material is dumped from the wheel barrows. Any space
between the chute and the edge of the opening in the floor through which it passes shall
be solidly planked over.
STAIRS, PASSAGEWAYS AND LADDERS
 Stairs and stair railings, passageways and ladders shall be left in place as long as possible.
 All stairs, passageways and ladders to be used by workmen during the process of
demolition shall be maintained in a safe condition.
 Ladders or their side rails shall extend not less than 1.0 m above the floor or platform to
which such ladder gives access.
 All ladders shall be secured/fastened against slipping/turning out at the bottom as well as
top end.
MECHANICAL DEMOLITION
 When demolition is to be performed by mechanical devices, such as weight ball and

power shovels, the following additional precautions may be observed.
 The building height should not exceed 25 m.
 The area shall be barricaded for a minimum distance of 1.5 times the height of the wall.
 While the mechanical device is in operation, no workman shall be allowed to enter the
building being demolished.
 The device shall be so located as to avoid falling debris.
 The mechanical device when being used shall not cause any damage to adjacent structure,
power line, etc.
94
Piling
Possible Hazards
 Slip
 Trip
 Fall
 Hit
 Impact
 Breaking of Fly wheels
 Noise
 Vibrations
 Body Intrusion and Abrasion
 damage to existing structures
 electrical hazards etc
General Requirement
 Clearance from Engineering& Projects Division, for protection of underground

facilities.
 Follow the applicable safety standard on excavation.
 Work site must be barricaded to prevent onlookers trespassing into the work site.
 All safety information must be displayed at a prominent place at the site .
 As per the requirement of the safety standard, all workers must wear tight fitting
cloths or uniform, helmets, hand gloves, protective footwear and eye protectors.
 Work site shall be illuminated with atleast 100 Lux intensity.
 For all electrical connections at site, one has to follow the safety standard on for
temporary electric wiring.
 left unattended, shall have an effective barrier.
 The legs of the tripod shall be firmly spiked in the ground and shall be examined
frequently by supervisors.
 Access to the top pulley Mud / slurry coming out during pile driving, shall be
stacked / dumped to a designated place.
 All holes, which are shall be provided by standard ladders with safety precaution.
 For all electrical connections at site, one has to follow the safety standard
SS/ELEC-01, on for temporary electric wiring .
 Mud / slurry coming out during pile driving, shall be stacked / dumped to a
designated place.
 All holes, which are left unattended, shall have an effective barrier.
 The legs of the tripod shall be firmly spiked in the ground and shall be examined
frequently by supervisors.
 Access to the top pulley shall be provided by standard ladders with safety
precaution.
 Piling machine operators should be over 21 years of age and should have
sufficient experience.
95
 While a pile is being hoisted, all workers not engaged in the work shall keep a
safe distance.
 All fitting appliances and lifting gear must have certificates of testing.
 Wherever, there are old structures (which are likely to be damaged during piling
operation) timely precaution to be taken.
 Measures shall be taken to ensure that there is no appreciable movement of soil mass
into the bore hole which may cause subsidence to any existing foundation in the
close proximity.
Frequency / Mechanism / Record / Responsibility
Before and During Piling activities :
Inspection and record to be maintained by Piling Contractors on daily basis.
All lifting machines / tools and tackles:
By competent person Once in a year (Test certificates)
Responsibilities: Consultant / Pilling contractors.
All exposed gears, flywheels, belts etc shall be fully machinery guarding by expanded
metal or wire mesh of small size (approx. max. 1/2 inch or 12 mm.) opening shall be
used all-around to prevent entry of hands and fingers.
96
HOUSEKEEPING
A good housekeeping programme plans and manages the orderly storage and movement of
materials from point of entry to exit. It includes a material flow plan to ensure minimal
handling. The plan also ensures that work areas are not used as storage areas by having
workers move materials to and from work areas as needed. Part of the plan could include
investing in extra bins and more frequent disposal.
The costs of this investment could be offset by the elimination of repeated handling of the
same material, and more effective use of the workers' time. Often, ineffective or insufficient
storage planning results in materials being handled and stored in hazardous ways. Knowing
the plant layout and the movement of materials throughout the workplace can help plan work
procedures.
Worker training is an essential part of any good housekeeping program. Workers need to
know how to work safely with the products they use. They also need to know how to protect
other workers such as by posting signs (e.g., "Wet - Slippery Floor") and reporting any
unusual conditions.
Housekeeping order is "maintained" not "achieved." This means removing the inevitable
messes that occur from time to time, and not waiting until the end of the shift to reorganise
and clean up. Integrating housekeeping into jobs can help ensure this is done. A good
housekeeping programme identifies and assigns responsibilities for the following:
 clean up during the shift;

 day-to-day clean-up;
 waste disposal;
 removal of unused materials;
 inspection to ensure clean-up is complete.
Effective housekeeping results in:
 reduced handling to ease the flow of materials;

 fewer tripping and slipping accidents in clutter-free and spill-free work areas;
 decreased fire hazards;
 lower worker exposures to hazardous substances;
 better control of tools and materials;
 more efficient equipment clean-up and maintenance;
 better hygienic conditions, leading to improved health;
 more effective use of space;
 reduced property damage by improving preventative maintenance;
 less work for cleaning staff;
 improved morale.
97
Differnent signs and symbols
Colour/Shape Meaning Instruction Examples
Prohibition sign Do not carry out

this action as it is
‘YOU MUST likely to increase or
Red circle & NOT’ cause danger.
diagonal on white
background
Warning sign Giving warning of a

hazard or danger.
‘CAUTION’
Black symbol and
border on yellow
background
Mandatory Specific action or

behaviour to be
‘YOU MUST undertaken
DO’
White symbol on
blue background
Information Indicate the way to

‘safe conditions’ or
White symbol on provision of
green background services
Identification and
Fire fighting
location of fire
equipment
fighting equipment
White symbol on
red background
98
Common reasons of slip, trip, fall

 Not Paying Attention while walking
 Use of Mobile Phone
 Not Holding Hand rails
 Poor House Keeping
 Open Pits
 Slippery or Damaged Floor
 Poor Illumination
 Not secured Ladder
 Improper or damaged Barricade at the platform
Common slip, trip, fall injuries
 Sprains and strains
 Bruises, contusions
 Fractures
 Abrasions, lacerations
Commonly affected Body Parts
 Knee, Ankle, Foot
 Wrist, Elbow
 Back
 Shoulder
 Hip
 Head
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BARRICATION
 Barricades are used as warning devices, alerting people of the hazards in the
construction sites. These are also used to control traffic movement on roads and to
protect hazard prone vital installations like gas holders, electrical sub-stations etc.
 Contractors are responsible for the installation of barricades.
 Consultants, site-in-charge from E&P Division and Departments are responsible to

ensure that the work site is properly barricaded by the contractors.
 Where required for protection of workers, public safety, or as required by laws,

substantial barricades shall be provided for the areas where excavation, trenching,
construction and demolition work is being performed.
 Barricades shall be provided to protect people from associated hazards and to

prevent trespassing into vital installations as per the requirement of prevailing laws.
 An opening measuring 30 cm or more in its least dimension, in any floor, platform,

pavement or yard through which person may fall; such as hatch way, stair or ladder
opening, pit or large manhole should be barricaded.
 Traffic flow shall be controlled by using appropriate barricades to guide the vehicles
into desired lane.
 All barricades shall be visible from a safe distance, to alert people well in advance.
 Caution board, division board, shutdown board to be displayed at both end of

barricade.
 Two persons with red / green flag and whistle to be deputed at both ends of the
barricades to regulate traffic.
 Red light to be provided on the barricades if job is to be done after sunset at the site.
 No material to be projected beyond barricades.
 Only authorized persons shall remove the barricades once the job is complete.
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Indicative Barricades
Cone Road Runner

Safety Tapes
Protective Barricades
Guard Rails Fencing

Types of barricade
Barricades can be classified into two groups viz a) Indicative Barricades and b)
Protective Barricades. Safety tape, portable steel frame barricades, portable road
barriers like cones, drums and road runners form the group of indicative barricades. Rail
guard, concrete guards, steel frame barricades grouted firmly onto the ground,
permanent fencing etc. form the group of protective barricades. Type of barricade is to
be selected depending upon the requirements and statutory provision.
Specific usage of barricades
Barricading Construction site

All construction sites are to be barricaded using the appropriate barricades, as given
in the following bullet points :
 Wherever construction debris is dropped without the use of an enclosed chute,

the area is to be barricaded using either of the barricade standards STD/020050,
STD/020051 or STD/020052 depending upon the availability of angle/square
hollow section and pipes, with 1 meter clearance from the deposited materials.
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 Areas with temporary wiring operating at more than 600 volts shall be
barricaded with indicative barricade comprising “Red-White” safety tape, if the
job requires at most one day to complete. If job requires longer time, then the
site is to be barricaded with protective barricades as per the above mentioned.
Plastic barriers must not be used to barricade the wok area.
 The swing radius of the rotating superstructure of cranes or other equipment is to
be protected using minimum 50 mm wide ‘Red-White’ safety tapes. One strand
of tape must run continuously from post to post at 1000 mm above ground.
Another strand of tape is to run above 300 mm from the ground.
 Excavations – A protective barricade of at least 1200mm high must be erected
around a trench that is 1 metre or more deep unless it is not possible or only
workers involved with the trench will be in the area; or another form of barrier
exists, for example, excavated materials near the trench. The required barricade
can be erected as per either of the standard drawing STD/020050, STD/020051
or STD/020051, depending upon the availability of the steel sections. This
barricade is to be firmly fixed with the ground with the help of pegs, as shown in
the drawing.
 Piling site is to be barricaded using indicative barrier for warning.
 Gas-cutting & Welding site shall be barricaded using minimum 50 mm wide
‘Red-White’ safety tapes for warning.
 For construction near/on roads refer Clause 6.3.3. of this standard.
Barricading Demolition site
 All the roads and open areas adjacent to demolition site shall be barricaded with
caution board. Unauthorized entry to demolition site must be prevented.
 Properly cover or securely barricade all floor or roof penetrations, lift shaft
entrances and doorways where staircases are to be removed.
 When floors are being removed, the area underneath shall be properly barricaded
to prevent any other workmen to work under the floor.
 All floor openings / wall openings shall be adequately guarded / barricaded and
provided Danger caution notices.
 During night, red light and/or luminescent danger signs shall be placed on and
around the barricades.
Barricading Roads
Before working on road or along road side, the contractor shall obtain approval for
working on road from safety department of Tata Steel. Barricade to control or to
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protect traffic is to be provided as per the norm mentioned below and to be approved
by the site-in-charge and the safety officer of the concerned department before
starting the job.
 Contractor shall make safe work procedure for the job with the help of the safety
officer of the concerned department.
 Care should be taken to block only one-half of road width at a time. Caution
board and division board is to be placed at both side of barricade.
 If entire road width is to be blocked, in addition to the caution board, the road
diversion sign is to be prominently placed on both ends of the work area.
 If access by construction vehicles is required, the contractor or agency doing the

work is responsible for properly replacing the barricades at the end of the
workday.
 If access to local office building is to be maintained beyond the point of the

closure then an adequate opening shall be provided between the barricades to
allow safe ingress and egress through the closure.
 Drum painted white with red stripes at the middle and barricade with red / white
safety tape may be used as barricade. However, barricades as shown either in the
standard drawings STD/020050, STD/020051 or STD/020052 are preferable to
drums.
 Two persons with red / green flag and whistle to be deputed at both sides of the
barricade to regulate traffic.
 Red light to be provided if job is to be done after sunset.
 No material to be projected beyond barricades.
 Barricade is to be provided around if equipment is left unattended near a
roadway at night.
 Rail guards, as per the standard drawing no.STD/020045, are to be permanently
placed in the ground, when road is passing parallel to railway track within 2
meter.
 For any work on a road near railway track or level crossing, the safety standard
SS/ENGG-14 on Rail Track Safety is to be strictly followed, including for
barricading the work site.
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Barricading water bodies
 Permanent rail guards as shown in the standard drawing STD/020045 are to be

grouted in the ground along the side of roads passing along water bodies like
lake, cooling pond etc. Same guards are to be placed on both sides of roads
running on the top of dam.
 For roads passing on the top of a dam, rail guards along with hand rails and mid
rails are to be fixed permanently on both side of the road.
All bridges crossing any stream or river, must have railings with hand-rail and mid-
rails.
An opening measuring 30 cm or more in its least dimension, in any floor,

platform, pavement or yard through which person may fall; such as hatch way,
stair or ladder opening, pit or large manhole should be barricaded.
Man hole Lift Well Floor Opening
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Portable electrical powered tools
Definitions
1. Portable Electric Motor-operated Tool: An electric motor operated machine so

desgined that the motor and the machine form an assembly which can be carried
by hand to the piece to be worked upon or to its place of operation.
2. Hand-Held Tool : An electric motor-operated tool intended to be held by hand

during normal operation.
3. Basic Insulation : An insulation applied to live parts to provide basic protection

against electric shock.
4. Functionally insulated parts: Metal parts that are separated from live parts by
basic insulation only.
5. Supplementary Insulation (Protective Insulation) : An independent insulation

applied in addition to the basic insulation in order to ensure protection against
electric shock in the event of a failure of the basic insulation.
6. Double insulation: Insulation comprising both basic insulation and

supplementary insulation.
7. Re-inforced insulation: A single insulation system applied to the live parts which
provides a degree of protection against electric shock equivalent to double
insulation.
Class I Tool: A tool in which protection against electric shock does not rely on basic
insulation only, but which includes extra safety, in that accessible conductive parts are
connected to theprotective earthing conductor in such a way that acessible conductive parts
can not become live in the event of failure of basic insulation. For tools intended for use with
a flexible cord or cable, this provision includes a protective conductor as part of the flexible
cord or cable.
Class II Tool:A tool in which protection against electric shock does not rely on basic
insulation only, but in which additional safety precautions, such as double insulation, re-
inforced insulation, are provided, there being no provision for protective earthing or reliance
upon installation conditions.
All-insulated (Class II A) Tool : A tool having durable and substantially continuous

enclosure of insulating material which envelopes all metal parts, with the exception of small
parts such as name plates, screws and rivets, which are isolated from the live parts by
insulation equivalent to at least equivalent to re-inforced insulation.
Metal-Encased (Double-insulated) (Class-IIB) Tool : A tool having a substantially

continuous metal eneclosure, in which double insulation is used through out except for the
parts where, the application of double insulation is manifestly impracticable, re-inforced
insulation is used. If a tool with double insulation and/or re-inforced insulation throughout
has an earthing terminal or earthing contact, the tool is deemed to be of class-I.
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Class III Tool: A tool designed for operation at safety extra-low voltage, and which has no
circuits, either internal or external, which operate at voltage other than safety extra-low
voltage.
Safety Extra-low Voltage: A nominal volatge not exceeding 32V between conductors, and
between conductors and earth, or for three phase supply 18.5V between conductors and
neutral, the no load voltage not exceeding 38V and 22V respectively.
Creepage distance: The shortest path between two conductove parts, or between a
conductive part and the bounding surface of the tool, measured along the surface of the
insulating material.
Rated voltage:For tools other than extra-low voltage, the preferred rated voltage shall be
240V for single phase and 415V for three phase. The preferred rated voltage for DC operated
tools shall be 220V.
General Requirement
 The tools must conform to IS standard or any international standards like

BS/ANSI/IEC/VDE etc.
 Prior to initial use, the tool must be inspected and tested for its suitability of use.
 Inspection and Testing include: electrical continuity and integrity of the chords, safety
guards, switches and other devices if so equipped, deformities and defects, proper
rotation (saws, drills, etc.) and sharpness (blades of cutting tools).
 Training to use electric tools is much more comprehensive than for hand tools. This
training can be accomplished by reading SOP (Safety operating procedures),
manufacturer’s opearting manual, by on the job training with a qualified person, or a
combination of all three. Training must include the PPE (Personal protective
equipment) and clothing requirements for each type of tools; gloves, safety glasses,
face shields or goggles and hearing protection.
 All hand-held tools shall be protected through maximum 30mA rating GFCI(Ground fault
circuit Interrupter)/ELCB(earth Leakage Circuit breaker). The minimum fault clearing
time shall be 500m Second.
 The Portable tools which are not hand held shall be protected through maximum 100mA
rating GFCI(Ground fault circuit Interrupter)/ELCB(earth Leakage Circuit breaker). The
minimum fault clearing time shall be 100m Second.
 Keep away from rotating or moving parts of the power tools.
 Do not touch the drill bit, blade, cutter or the Workpiece immediately after operation.
They may be extremely hot and may burn the operator.
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Construction and Material:
Electrical Insulation:
 Wood, Cotton, silk, paper, and similar fibrous or hygroscopic material shall not be
used as insulation, unless effectively impregnated.
 Tool shall be so constructed that internal wiring, windings, commutators, slip rings
etc, and insulation in general or not exposed to oil, grease, or similar substances.
 Tools shall be so constructed that should the conductor strands, brush shunts,screws,
washer, springs and the like loosen or become free, they shall not bridge any
insulation between live parts and acessible metal parts.Loossening of these parts shall
not reduce clearnaces or creepage distance between live parts and accessible metal
parts to less than 50 percent of the value specified in clause-18 of IS:4665-Part-I.
 Protective class-II tools shall be securley fixed in such a way that it can not be
removed without being seriously damaged or without making the tool unfit for
further use. The requirement is met if the insulation is so fixed that it can be removed
only by breaking or cutting.
Handles
Handles, levers and the like shall be fixed in a reliable manner so that they do not work loose
as result of heating, vibration etc, ocuuring in normal use.
Brush Gear
 The carbon brushes shall conform to IS:3003 (Part-III).

 It shall not be possible to gain acess to brushes without the use of a tool.
 Screw type brush caps which are acessible from the outside of the tool shall be of
insulating material. It should not project beyond surrounding surface of the tool.
 Brushes holder and their caps shall have adequate mechanical strength as defined in
the clause 5.3.3 of IS:4655 (Part-I).
Switches
 Every tool shall be provided with a switch on a body suitable for frequent operation.
 The switches shall have adequate breaking capacity. On single phase tools the switch
shall disconnect both the poles. However single pole switch is permitted for Class-II
and class-III tools.On three phase tools two pole switching is permitted.
 Tools designed for use on DC only or on DC/AC shall be fitted with switches of quick
make and break type. Slow make and break switches may be fitted to tools designed
for use soleley on AC supply.
 The switches for hand-held tools shall be so located or guarded that their accidental
operation is unlikely.
 Switches for hand-held tools shall be arranged to return automatically to the OFF
position on release, except on such tools where the type and nature of work make such
an arrangement undesirable or where the continuous running of the tool is not
dangerous.
107
Change of Settings
It shall not be possible to alter the voltage setting without the use of tool. The tool which can
be set for the opposite direction of rotation shall be so constructed that any accidental
changing of the setting is obvious to the user.
Radio Interference Suppressors
Radio and Television interference suppressors when fitted shall be located inside the
enclosure of the tool or in a strong casing firmly fixed on the tools.
Internal wiring
 The basic insulation of internal wiring shall be at least equivalent to the minimum
insulation for flexible cords given in IS:9968 (Part-I)-1981 and IS:694-1977.
 Internal wiring and electrical connection between different parts of the tool shall be
adequately protected or enclosed against mechanical damage.
 Wireways shall be smooth and free from sharp edges, burrs, flashes etc, which may
cause abrasion to the insulation of conductors.
 Wireways shall be effectively prevented from coming into contact with the moving
parts.
 Holes in sheet metal through which insulated wires pass shall be provided with
bushing of insulating material.
Mechanical Strength
Tools shall have adequate mechanical strength and shall pass the Tests specified in Clause-
20.12 of IS:4665 (Part-1) -1984.
Protection against Moisture:
Tools shall be so constructed that they are proof against ingress of moisture that may ocuur in
normal use. The tool should comply the Tests specified in Clause- 20.9 of IS:4665 (Part-1) -
1984.
Resistance to Heat:
External parts and parts of insulating material supporting live parts shall be resistant to heat
and shall pass the Test specified in Clause- 20.16 of IS:4665 (Part-1) -1984.
Protection against Electric Shock
 Enclosure of tool shall have no openings other than those necessary for use and
working of tool. Where such openings are necessary, sufficient protection shall be
provided against accidental contact with live parts.
 Enamel, paper, cotton and similar coverings are not deemed to provide adequate
protection for the purpose of the above requirement.
108
 Parts providing protection against accidental contact with the live parts shall have
adequate mechanical strength and shall not work loose in normal use. It shall not be
possible to remove these parts without use of tool.
 Metal shafts, operating knobs, handles, levers and the like shall not be live. They shall
be earthed and separated by atleast functional insulation from live parts of Class-I
tools. They shall be separated by protective insulation from functionally insulated
parts and by double insulation or re-inforced insulation from live parts on double and
all insulated Class-II tools.
 All hand-held tools shall be protected through maximum 30mA rating GFCI(Ground
fault circuit Interrupter)/ELCB(earth Leakage Circuit breaker). The minimum fault
clearing time shall be 500m Second.
 The Portable tools which are not hand held shall be protected through maximum
100mA rating GFCI(Ground fault circuit Interrupter)/ELCB(earth Leakage Circuit
breaker). The minimum fault clearing time shall be 100m Second.
Provision for Earthing:
 The provision for earthing is not necessary for Class-II and Class-III tools.
 Acessible metal parts of Class-I tool shall be provided with permanent and reliable
earthing terminal as close as supply terminal as possible. In case if tool is operated at
voltage in excess of 250V, two separate earthing terminals shall be provided.
 The body of terminal shall be of brass. The screw or nut shall also be of brass.
 When the body of earthing terminal is a part of metal frame or enclosure made of
Aluminium or Alluminium alloy, special precaution shall be taken to avoid the risk of
corrosion resulting from contact between copper and Aluminium.
 It shall not be possible to loosen the earthing terminal screw without the use of tool.
 Flexible cords or cables of Class-I tools shall be provided with an earthing conductor.
Power Input and current:
The power input at normal load at rated voltage or at upper limit of rated voltage range shall
not exceed the rated input of the tool by more than the deviation given below:---
Rated power (Watt) Deviation

Up to and including 33.3 10W
Over 33.3 up to and including 150 30 percent
Over 150 up to and including 300 45W
Over 300 15 percent
109
 The input current at normal load at rated voltage or at the lower limit of the rated
voltage shall not exceed the rated current by more than 15 percent.
 The measured slip of the induction motor of the tool shall not be more than ±50% of
the stated slip at full load.
 The measured speed, in case of universal motor shall not be more than ±20% of
guaranteed speed at full load.
Marking
Tools manufacturedin compliancewith the IS:4655 shall be marked clearly and indeliably
with the following:-----
a) Refernce to IS standard;
b) Manufacturer’s name or trade mark;
c) Manufacturer’s model or Type reference;
d) Rated voltage or voltage operating range;
e) Nature of supply;
f) Rated frequency;
g) Rated input in Watts;
h) Rated current in Ampere;
i) Rated operating and resting time in hours, minutes or seconds, if to be observed;
j) Degree of protection against ingress of water;
k) Tools intended for either delta or star connections shall be clearly marked with two
rated voltages (for example, 415 and 240V);
l) No load speed;
m) Country of origin;
n) Symbol for Class-II construction if appliacble.
Note: All-insulated and double-insulated tools shall be clearly marked “DO NOT EARTH----
-ALL-INSULATED, or “DO NOT EARTH------ DOUBLE INSULATED”.
110
When the symbols are used, they shall be as follow:--
Parameters Symbol
Alternative current ~
AC / DC ~
Three – phase alternative current 3~
Three – phase alternative current 3N ~
Direct current –
Class – II construction
Drip – proof construction (one drop) 
Splash – proof construction (one drop in

triangle) 
Watertight construction (two drop) 
Earthing
 Tools to be connected to more than two supply conductors shall be provided with
wiring diagram.
 For tools with Star-delta connection the wiring diagram shall also show how the
winding shall be connected.
 Tools may also be marked with the ISI Certification mark.
Routine Test
Unless otherwise specified in the individual specification routine test as follows shall be
carried out on all completed tools:---
The tool shall be run on no load at rated volatge for at least 20 cycles of 100 seconds: ON and
20 seconds OFF. An ac voltage as specified below shall then be applied for 1 second between
live parts an body of the tool. The test is carried out normal room temperature:
Class-I Tools ---------- 1500 Volts

Class-II Tools ---------- 4000 Volts
Class-III Tools ---------- 500 Volts
No flashover or breakdown of insulation shall occur.
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Safety for the Battery Operated Cordless Tools

Cord less tools get their electrical power from Batteries. Cord less tools are also capable of
causing injury if all safety precautions are not followed. Following safety precaution shall be
followed while operating Battery operated tools:----
 Read and understand thoroughly the instruction manual for its operation and safety
precaution.
 Perform charging of the battery in dry location, away from combustible material.
 If the battery of the tool no longer re-charges properly with its specified unit then
contact the supplier of the Tool or its service centre for rectification.
 Do not operate cordless tool in or near flammable liquids or in gaseous or explosive
atmospheres until these tools are specifically designed for such application. Motors in
these tools normally spark and sparks may ignite fumes.
 Always recharge a cordless tool and its battery with its own specified charging unit.
Never attempt to re-charge a cordless tool in a re-charging unit not specifically
recommended for that tool or battery pack by the manufacturer.
 Keep both tool and re-charging unit in an area not accessible to in-experineced
persons.
 Beaware that cordless tool can always be in an operating condition because it does not
have to be plugged into an electrical outlet. Unless the Batteries are removed tool can
function at any time switch is turned on.
 Remove batteries or lock the switch in “OFF” position before changing the
accessories, adjusting or cleaning the tool. This removes the power supply while
hands are in vulnerable locations such as near switches, bits or blades.
 Do not short the battery pack. A battery pack short can cause a large current flow,
overheating, and possible burns or fire.
 Do not touch the battery terminals with any conductive material.
 Do not store the battery pack in a container with metal objects such as wires, nails etc.
 Do not incinerate battery pack or throw into water even if it is damaged or completely
worn out. Battery pack can explode in a fire.
Training
Personnel who use portable tools must be trained in their proper use, maintenance,
inspection techniques, and PPE requirements. It is the responsibility of the user’s
supervisors/management to develop and conduct the training programme and SOP’s for
each type of tool used including “Ground Fault circuit interrupters” for safe tool opeartion.
112
WORKING AT HEIGHT
Definitions
Anchorage
A secure point of attachment, not part of the work surface, to which lifelines, drop lines, or
lanyards are affixed. An anchorage must be capable of supporting a minimum dead weight of
5,000 pounds (2,268 kilograms) for every person attached to it. An anchorage not meeting the
5,000 pound requirement must be part of a complete personal fall arrest system which
maintains a safety factor of at least two and is designed and used under the supervision of a
qualified person. An anchorage is often a beam, girder, column, or floor.
Anchorage Connector
A component or device that is installed on an anchorage and is specifically intended for

attaching a fall-arrest system to the anchorage. Anchorage connection straps, carabineers, and
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girder grips rated to support minimum dead weight of 5,000 pounds (2,268kilograms) can be
purchased from fall-protection equipment manufacturers.
Carabineer
A trapezoid- or oval-shaped connector component with a gate or similar arrangement that

remains closed until it is intentionally opened for connection or disconnection.
Deceleration Device
Any mechanism, such as a rope grab, rip-stitch lanyard, specially-woven lanyard, tearing or
deforming lanyards, automatic self-retracting lifelines/lanyards, etc., which serves to
dissipate a substantial amount of energy during a fall arrest, or otherwise limit the energy
imposed on an employee during fall arrest.
Descent Device
A device or piece of equipment used to escape from an elevated structure such as a work
platform, tower, column, or an overhead crane cab.
Personal Fall-Arrest System
A system used to arrest a fall from a working level. A personal fall arrest system consists of
an anchorage, connectors, a body harness, and may include a lanyard with a locking snap
hook, deceleration device, lifeline or suitable combination of these.
Fall Hazard
A condition or situation that could result in a fall.
Fallout
An unintentional separation of a person from a body-support component during or after fall

arrest.
Fall Prevention
Eliminating fall hazards during all phases of work at heights, including access and egress.
Examples of fall prevention measures include using complete scaffolds, aerial lifts, and
secured ladders.
Free Fall –
An unarrested fall.
Harness (Full-Body)
A device with straps that can be attached to a personal fall-arrest system. The straps are
fastened around a person's body to contain the torso and distribute fall-arrest forces over at
least the upper thighs, pelvis, chest, and shoulders.
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Leading Edge
The edge of a floor, deck, or grating that changes location as additional floor or deck sections
are placed.
Lifeline
A flexible vertical or horizontal line, secured to an anchorage or between two anchorages, to

which a lanyard or harness may be attached. A catenary lifeline is a lifeline used in a
horizontal position that is secured between two anchorages. A lanyard can be attached to a
catenary lifeline by using a sliding connection or by tying off.
Positioning Device System
Equipment that allows a person to work with both hands free while standing in such a way
(for example, leaning backwards) that a fall could result. Positioning device systems are often
used on framework construction and concrete rebar placement.
Retractable Lifeline
Afall-arrest device that allows free travel without slack rope, but locks instantly when a fall
begins. Retractable lifelines may be used when vertical movement is required but must be
limited, such as in tanks, manholes, and pressure vessels, or on roofs.
Rollout
A process by which a snap hook or carabineer unintentionally disengages from another

connector or object.
Rope Grabs (Fall-Arrester)
Automatic lifeline devices that act by inertia to grab the lifeline if a fall occurs. Rope grabs
are used when vertical movement is required, such as work from boatswain chairs or
suspended scaffolds.
Self-Locking Snap Hook
A hook-shaped connector with a gate or similar arrangement that remains closed and locked
until it is intentionally opened for connection or disconnection. When the gate is released, it
automatically closes.
Shock-Absorbing Lanyard
A flexible line that secures a person wearing a harness to an anchorage, anchorage connector,
lifeline, or dropline, with an integral energy shock absorber that limits shock load forces on
the body. Most energy shock absorbers are made of a webbing material with tear-away
stitching designed to gradually absorb the fall-arrest load. A lanyard must have a nominal
breaking strength of 5,000 pounds (2,268 kilograms) and may be nylon or Dacron® rope,
flexible aircraft steel cable, or webbing.
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Steps to take before working at height
 Check there is a safe method of getting to and from the work area.
 Decide what particular equipment will be suitable for the job and the conditions on
site.
 Make sure work platforms and any edges from which people are likely to fall have
guard rails and toe boards or other barriers.
 Due considerations to be given for scaffolding and ladder standards as reference.
 Make sure that the equipment needed is delivered to site in good time and that the site
has been prepared for it.
 Check that the equipment and body Harness is in good condition and make sure that
whoever puts the equipment together is trained and knows what they are doing.
 Make sure those who use the equipment are supervised so that they use it properly.
The more specialized the equipment (for example, boatswain's chairs and rope access
equipment), the greater the degree of training and supervision required to ensure
safety.
 Check any equipment provided by another company is safe on site before using it.
 Find out who to tell if any defects need to be remedied or modifications need to be
made and keep them informed.
When selecting a means of access, remember:
 only when it is not practicable to provide a work platform with guard rails should
other means of access (for example, boatswain's chairs or rope access techniques) be
used;
 only when no other method is practicable, or risk assessment shows other methods are
safer when work platforms cannot comply with all requirements for safe work (e.g. a
guard rail has to be removed to land materials), should a way of arresting falls (for
example, a harness and lines or nets) be relied upon;
 If no other means of providing a safe place of work at height is available, then
appropriately anchored harness should be worn. However, whenever harnesses are
used a method must be available to enable people to be rescued should they fall and
be left suspended in their harness
 Nets may also be needed to protect those working to put guard rails or other
protection in place;
 Ladders should always be secured if possible. They should be primarily used for
access and only be used as workplaces to do light work of short duration, and then
only if it is safe to do so. It is generally safer to use a tower scaffold or MEWP even
for short-term work. Heavy work activity such as drilling or carrying heavy loads
should never be carried out from a ladder. When using a ladder ensure that the person
on the ladder always has three points of contact, i.e. two legs and a hand. People
should never have to lean sideways when up a ladder.
 When selecting a safe system of work at heights, all the risks have to be considered
before one method is selected. For example, if nets are selected, is there adequate
clearance under the nets to prevent injury to those who may fall into them? If
harnesses are used, is there sufficient clearance from the ground to allow the shock
absorbing lanyard or inertia reel to fully extend?
 Before any work at height, check that there is adequate clearance for equipment. For
example, overhead power lines can be a risk when erecting scaffolds or using
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MEWPs; there can be a risk of crushing against nearby structures when mobile access
platforms are maneuvered.
 Work permit for working at height shall be issued in the approved format before start of
the job by the authorized person of the department in duplicate. The original shall be
issued to working agency while the copy shall be kept by the issuing authority.
Following checks shall be carried out before issuing permit.
(1) Personnel skill
(i) Whether the Person is a certified rigger.
(ii) Whether Person is fit for working at height (ask for certificate from Doctor
whether the person has vertigo-height phobia, for working at height more
than 3 meter).
(iii) Person is trained on working at height.
(2) Suitability of approach.
(i) Physical condition and suitability of steps, rung ladders.
(ii) Scaffolding ,ramps, stairs with respect to load
(3) Suitability of platform
(i) Whether handrails provided at 0.9 meter height with top rail middle rail and
toe guard.
(ii) Whether extended support roof/working platform fabricated or available.

(iii)Whether secondary support provided while working at fragile or hazardous
roof.
(4) Availability of PPE and tools.
(i) Helmet with chin strips, in working condition.
(ii) Safety belt with arrangement for life line support.
(iii) Fall arrester.
(5) Communication.
(i) Hazard of nearby work vicinity has been identified like, power line, power
mobile equipment, gas line, etc. and proper care has been taken and same
communicated to persons expected to work at height.
(ii) Operator of mobile equipment in the close vicinity informed about job
being done.
(iii) Area on ground beneath the height where job is being executed, has been
properly barricaded/fenced indicating danger.
(iv) Concerned departmental personnel whose work may get affected by the
job have been identified and communicated.
 Permit shall be issued only if the findings of the above checks satisfy the issuing
authority.
 If working at height includes gas cutting and welding, working in gaseous hazardous
area, near electrical installation, work permit should be obtained from authorized
agencies separately for each hazard.
 Work permit shall be returned daily after completion of job. The work permit issuing
authority of owning department, after completion of the job, shall complete the form by
filling part (E) in the original along with the white copy.
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Continuous Fall Protection
General
Fall protection can be achieved through eliminating fall hazards, preventing falls, and
controlling falls. Eliminating fall hazards is the most desirable of these three, but it is also
difficult. If fall hazards cannot be entirely eliminated, potential falls must be controlled by
using fall-arrest systems. Consult the site safety specialist before purchasing fall-arrest
systems. All components of fall-arrest systems must meet the appropriate governmental
regulations and consensus standards.
Systematic Approach to Continuous Fall Protection
Every employer must take a three-step, systematic approach to protecting people from falls.
Eliminate Fall Hazards
The first step in this approach is to assess carefully the workplace and the work itself in the
earliest design/engineering stages of project work and during the planning stages of all work.
The objective is to eliminate all fall hazards. Ask “who, what, when, where, why, how, and
how much” questions about each possible exposure to a fall. This assessment of the site and
the work not only helps eliminate hazards, but also identifies alternative approaches to the
work that can measurably enhance productivity. Addressing fall protection in the early phases
of a project means that safety can be designed into the work process, not added as an
afterthought to an inherently unsafe work procedure. For example, the project can be
designed so that structural steel can be assembled at grade and then raised as a “module,”
thus eliminating a significant amount of work at heights.
Prevent Falls
The second step in continuous fall protection also requires assessing the workplace and work
processes. If fall hazards cannot be completely eliminated during the first step, try to prevent
falls by improving the workplace. Avoid relying on a worker's behavior or fall-arrest
equipment to prevent injuries. Early installation of stairs, guardrails, barriers, and travel
restriction systems can ensure a safe work environment.
Use the Proper Fall-Arrest Equipment
The third step, the last line of defense against falls, is to use fall-arrest equipment. Use fall-
arrest equipment, however, only after determining that potential falls cannot be eliminated by
changing work procedures or the workplace. Equipment such as harnesses, lanyards, shock
absorbers, fall arresters, lifelines, anchorages, and safety nets can reduce the risk of injury if a
fall occurs. Carefully assess the workplace and work processes to select the most appropriate
equipment and to install and use it correctly.
Preparing Written Fall-Protection Plans
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Prepare fall-protection plans for elevated work if fall hazards exist. Where fall hazards are
significant, the plans should be in writing. Site management/ supervision is responsible for
determining which jobs require written plans. The requirement for written plans should be
included in all applicable contracts.
Training Employees
Provide a training program for all employees who will be exposed to fall hazards. Explain
that while slipping or tripping at ground level occurs more frequently than falls from heights,
the injuries are generally not as severe. Workers must be trained to recognize the hazards of
falling from heights and to avoid falls to lower levels through holes or openings in walking or
working surfaces and walls. Training programs should include prevention, control, and fall-
arrest systems. Make sure that appropriate fall arrest systems are installed and that employees
know how to use them before beginning any work that requires fall control.
Eliminating Fall Hazards and Preventing Falls
Engineers and designers may require special training to recognize fall hazards, to understand
fall prevention techniques, and to become familiar with fall-arrest equipment and procedures.
It is critical that they consider fall protection design for the safety of construction and
maintenance workers who must work at heights, including workers’ safety during access and
egress from elevated work sites. Use the following guidelines when planning work at heights:
– Involve safety specialists early in the project planning so they can recommend appropriate
fall-protection measures and equipment.
– Use the expertise of fall-protection equipment manufacturers and distributors.
– Be specific in dealing with fall hazards when developing contracts. Require contractors to
prepare written fall-protection plans, especially with roofing work, construction of cooling
towers, erection of steel structures, and fabrication and erection of tanks and boilers.
– Specify and insist that fabricators supply permanent stairs and guardrails before steel is
erected. In this way, the stairs and steel can be erected simultaneously, improving not only
safety but also efficiency. The ironworkers will have safe access and egress and the necessity
of climbing temporary ladders will be reduced or eliminated.
– Make sure temporary perimeter protection is effective. For example, when cable guard rails
are used, weld the cable support brackets or drill holes in the columns while the steel is at the
fabrication shop or on the ground at the work site. Avoid welding cable supports after the
steel has been erected. (Check the design before drilling holes in columns.)
– Design and build permanent guardrail systems to meet the requirements of Tata Steel
Standard.
– Attach lifelines to steel columns while the steel is on the ground to provide tie-offs for
ironworkers unless other methods of fall protection are provided.
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– Provide work platforms for electricians who install cable trays and pull wires into elevated
cable trays.
– Use complete scaffolds and aerial lifts to provide safe work platforms.
– Construct and install hole covers immediately after creating the holes.
Controlling Falls
When fall hazards cannot be eliminated through design and engineering or through the
techniques discussed above, the fall-arrest systems discussed in this section must be used to
control falls. An automatically controlled descent device that limits descent speed to 6 feet
(1.8 meters) per second for a 300-pound (136-kilogram) person should be used in all
situations that require emergency egress.
Personal Fall-Arrest System
A personal fall arrest system consists of an anchorage, connectors, a full-body harness, and
may include a lanyard with locking snap hook, deceleration device, lifeline or suitable
combination of these. The use of a body belt for fall protection is prohibited. Before using a
personal fall arrest system, the supervisor and/or the user must address the following
questions:
– Has the user been trained to recognize fall hazards and to use a personal fall-arrest
systemproperly?
– Are all components of the system compatible according to the manufacturer's instructions?
– Have appropriate anchorage points and attachment techniques been reviewed?
– Has the free-fall distance been considered so that a worker will not strike a lower surface or
object before the fall is arrested?
– Have pendulum-swing fall hazards been eliminated?

– Have safe methods to retrieve fallen workers been planned?
– Have the full-body harness and all of its components been inspected both before each
useand on a quarterly basis?
– Is any of the equipment, including lanyards, connectors, and lifelines, subject to such
problems as welding damage, chemical corrosion, or sandblasts?
Retractable Lifelines :- A retractable lifelines a fall-arrest device used in conjunction with

other components of a fall-arrest system. A retractable lifeline should be used by only one
person at a time. The retractable lifeline must be connected directly to the back D-ring of the
safety harness and never used in conjunction with or connected to a shock absorbing lanyard.
A properly inspected and maintained retractable lifeline, when correctly installed and used
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within the fall-arrest system, automatically stops a person’s descent in a short distance after
the onset of a fall. Consider using retractable lifelines when working in or on areas such as
roofs, scaffolds, tanks, towers, vessels, and manholes. Also, consider using retractable
lifelines when climbing such equipment as vertical fixed and portable ladders and telescoping
derricks. The retractable lifeline must not be used again after it has worked as fall arrester
once. Before using a retractable lifeline, the supervisor and/or the user must address the
following questions:
- Has the user been trained to use a retractable lifeline correctly?
- Is the retractable lifeline being used in conjunction with a correctly configured fall arrest
system?
- Is the equipment under a regular maintenance program?
Ladder Safety Systems
A ladder safety system can be attached to a permanently installed ladder or to a rigidly

installed portable ladder. The system provides continuous protection while a person ascends
or descends the ladder by automatically locking and arresting a fall.
Safety Net Systems
A safety net system is the least desirable fall-arrest system. If used, the system must be
installed as close as practical under the walking or working surface. A safety net system must
never be more than 30 feet (9.1 m) below the working surface (except for bridge
construction). Safety nets shall be capable of absorbing an impact force equal to that
produced by a drop test. The test shall be conducted by dropping a 400-pound (180 kg) bag of
sand 30 +/- 2 inches (76 +/- 5 cm) in diameter into the net from the highest walking or
working surface at which employees are exposed to fall hazards. The drop distance shall
never be less that 42 inches (1.1 m) above the net level. A drop test must be conducted after
initial installation and before use, whenever relocated, after major repair, and at six-month
intervals if left in one place. Safety nets shall be inspected at least once a week for wear,
damage, and other deterioration. Materials, scrap pieces, and equipment and tools, which
have fallen into the safety net, shall be removed as soon as possible but at least before the
next work shift. Before using a safety net, the supervisor and/or the user must address the
following questions:
– Are workers protected from fall hazards while they install and dismantle the safety net
system?
– Is the safety net installed as close as practical under the working surface?
– Is there sufficient clearance under the net to prevent contact with surfaces or objects below
if
the net is subjected to an impact equal to that imposed under the required drop test?
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– Does the safety net extend beyond the outermost projection of the work surface? For
vertical distances of up to 5 feet (1.5 meters) between the net and the work surface, the
minimum required horizontal distance from the net's outer edge to the working surface edge
is 8 feet (2.4 meters). For vertical distances between 5 and 10 feet (1.5 meters and 3 meters),
the horizontal requirement is 10 feet (3 meters). For vertical distances greater than 10 feet (3
meters), the horizontal requirement is at least 13 feet (4 meters).
– Are the safety net supports designed so that a fall victim will not land on them?
– Has the manufacturer or supplier of the net been consulted for assistance and
recommendations concerning the proper type of net and proper installation and testing?
Lifeline Installation
Horizontal and vertical lifelines shall be designed, installed, and used under the supervision
of a qualified person as part of a complete personal fall arrest system. Horizontal lifelines
allow horizontal movement while providing protection against falls provided the equipment
is properly installed and used. A horizontal lifeline may serve as a mobile fixture point for the
attachment of lanyards, lifelines, or retractable lifelines. A lifeline must be wire rope of at
least 1/2-inch (1.27-centimeter) diameter, or its equivalent, and must maintain a safety factor
of at least two. Vertical lifelines extend from an overhead independent anchorage and should
be maintained in a vertical position while in use. A lanyard is attached to a vertical lifeline
using a rope grab device. No more than one person may tie-off to a vertical lifeline. A
vertical lifeline must have a minimum breaking strength of 5,000 pounds (2,268 kilograms).
Anchorage
Anchorages used for attachment of personal fall arrest equipment shall be independent of
any anchorage being used to support or suspend platforms. Anchorages must be capable of
supporting at least 5,000 pounds (2,268 kilograms) per employee attached, or shall be
designed, installed, and used as follows:
- Part of a complete personal fall arrest system that maintains a safety factor of at least two.
- Under the supervision of a qualified person.
Most Common and Most Dangerous Fall Hazards
The tasks and situations listed in this section present inherent fall hazards. Give special
attention to providing fall prevention and fall control, remembering that this attention is
necessary in the design, engineering, planning, and execution stages of work.
– Installing, painting, and insulating pipe systems such as overhead cranes, presses, furnaces,
conveyors, and monorails
– Doing other work that involves fall hazards, including tank erection, form work, masonry
work, and work above ceilings For many of the above examples, elimination of the fall
hazard will be difficult. The use of completed scaffolds, aerial lifts, etc. can minimize the
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hazard but may not eliminate it totally. In these cases, the use of personal fall arrest
equipment is required. In cases where employees are required to move in unprotected areas,
the use of double lanyards is required to achieve 100 percent fall protection. This allows
workers to move from one location to another but also keeps them secured at all times. This
is achieved by the employee connecting one lanyard to a suitable anchorage point before
disconnecting the other lanyard. Examples of where use of double lanyards would be
appropriate are scaffold erection, steel erection (for that work not done from protected areas),
and moving in a pipe bridge or cable tray.
Erecting and Dismantling Scaffolds
Give special consideration to fall protection for workers who assemble and disassemble
scaffolds. Make sure workers who install, dismantle, inspect, maintain, and use scaffolds
receive appropriate instructions, including relevant requirements.
Erecting Cooling Towers
Employers must provide adequate access and egress, lifelines, temporary perimeter
protection, and other fall protection for those who are erecting a cooling tower. Contracts
must require that the contractor provide a written fall-protection plan.
Recommended Manufacturers and Models of Fall-Protection Equipment
Numerous vendors carry full lines of fall-arrest equipment, including anchorage connectors,
retracting lifelines, rope grabs, controlled descent devices, safety nets, full-body harness
systems, and boatswain chairs. For additional information concerning fall protection
equipment, contact the manufacturers who can provide catalogs and training assistance.
Standard Harnesses
Harnesses for general purpose work should be constructed with back D-ring, integral hip D-
rings for work positioning capability, and tongue-buckle thigh straps. Standard harnesses are
suitable for continuous fall protection while climbing, riding, or working on elevated
platforms. They are suitable for positioning, fall arrest, and the rescue and evacuation of
people who are working at heights.
Standard Lanyards
Lanyards should be 1- inch (2.5-centimeter) straps, adjustable up to 6 feet (1.8 meters). They
should also have shock-absorbing capability and self-locking snap hooks.
Wire Rope Shock-Absorbing Lanyards
Consider using 6-foot (1.8-meter) wire rope shock absorbing lanyards with self-locking snaps
for welding, burning, or other heat-producing activities.
Work-Positioning Lanyards
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Work positioning lanyards are recommended for restraining purposes and for attaining
stability, but not for arresting falls. Connect a work-positioning lanyard to two hip D-rings
and use it in conjunction with a fall-arrest lanyard.
Safe working platforms
Working platforms are the parts of structures, Mobile Elevating Work Platforms (MEWPs),
cradles etc upon which people stand while working. As well as being adequately supported
and provided with guard rails or barriers, working platforms should be:
 wide enough to allow people to pass back and forth safely and to use any equipment
or material necessary for their work at that place and in any case, at least 600 mm
wide
 free of openings and traps through which people's feet could pass, causing them to
trip, fall or be injured in any other way
 Constructed to prevent materials from falling. As well as toe boards or similar
protection at the edge of the platform, the platform itself should be constructed to
prevent any object which may be used on the platform from falling through gaps or
holes, causing injury to people working below. For scaffolds, a close-boarded
platform would suffice, although for work over public areas, a double-boarded
platform sandwiching a polythene sheet may be needed. If MEWPs or cradles are
used and they have meshed platform floors, the mesh should be fine enough to
prevent materials, especially nails and bolts, from slipping through
 kept free of tripping and slipping hazards. Where necessary, provide handholds and
footholds.Keep platforms clean and tidy. Do not allow mud to build up on platforms.
Mobile and suspended access equipment
Where it is not possible to work from the existing structure and the use of a scaffold working
platform is not appropriate, a range of mobile access equipment including mobile elevating
work platforms (MEWPs), suspended cradles, mast climbing work platforms (MCWPs),
boatswain's chairs or seats, and rope access equipment can be used.Those using this type of
equipment should be trained and competent to operate it. They should learn emergency and
evacuation procedures so that they know what to do, for example, if the power to the platform
fails, or fire breaks out in the building being worked on. With many pieces of equipment,
more than one person will be needed to ensure safe operation.
Before work starts
Check that:
 a handover certificate is provided by the installer. The certificate should cover how to
deal with emergencies, operate, check and maintain the equipment, and state its safe
working load;
 equipment is installed, modified and dismantled only by competent specialists;
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 there is a current report of thorough examination for the equipment;

 areas of the site where people may be struck by the platform or falling materials have
been barricaded.
 systems are in place to prevent people within the building being struck by the
platform as it rises or descends and prevent the platform coming into contact with
open windows or similar obstructions which could cause it to tip;
 supports are protected from damage (for example, by being struck by passing vehicles
or by interference from vandals);
 the equipment can be protected from adverse weather. High winds can tilt platforms
and make them unstable. Establish a maximum safe wind speed for operation and do
not work when there is lightening. Storms and snow falls can also damage platforms,
so they should be inspected before use after severe weather.
At the end of each day
Check that:
 The platform is cleared of tools and equipment;

 All power has been switched off and, where appropriate, power cables have been
secured and made dead;
 The equipment is secured where it will not be accessible to vandals or trespassers;
 Notices are attached to the equipment warning that it is out of service and must not be
used.
 Check the shift report for warnings of malfunction etc.
Mobile elevating work platforms (MEWPs)
Mobile elevating work platforms (MEWPs) can provide excellent safe access to high level
work. When using a MEWP make sure that:
 whoever is operating it is fully trained and competent;

 the work platform is provided with guard rails and toe boards or other suitable
barriers;
 it is used on firm and level ground. The ground may have to be prepared in advance;
 its wheels are properly inflated;
 The working platform is sufficiently away from electric lines.
 any outriggers are extended and chocked as necessary before raising the platform; and
 everyone knows what to do if the machine fails with the platform in the raised
position.
Do not:
 operate MEWPs close to overhead cables or other dangerous machinery;

 allow a knuckle, or elbow, of the arm to protrude into a traffic route when working
near vehicles;
 move the equipment with the platform in the raised position unless the equipment is
designed to allow this to be done safely (check the manufacturer's instructions).
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Some MEWPs are described as suitable for 'rough terrain'. This usually means that they are
safe to use on some uneven or undulating ground - but check their limitations in the
manufacturer's handbook before taking them onto unprepared or sloping ground. Wearing a
harness with a fall restraint lanyard attached to the platform can provide extra protection
against falls, especially while the platform is in motion.
Mast climbing work platforms
This equipment is often used when carrying out repairs to or refurbishment of high rise
buildings. MCWPs are designed to provide access to working positions - they are not
designed to act as material hoists.
Only specialists should erect, alter or dismantle mast platforms. It is particularly important
that the correct sequence is followed. Serious accidents have occurred when ties have been
removed or outriggers have not been properly extended during alterations.
A great advantage of using mast platforms is that those using them can be protected from
adverse weather as many types can be provided with screens and a roof to the platform.
Enclosures to platforms can increase wind loads. The supplier must always be consulted
before fixing them.
When mast platforms are used, make sure:
 masts are rigidly connected to the structures against which they are operating and
outriggers are used when necessary;
 working platforms are provided with suitable guard rails and toe boards;
 the controls only operate from the working platform; and
 the area below the platform is barricaded to protect people from objects that may fall
from the platform.
Temporarily suspended access cradles and platforms
Accidents happen during installation, use and dismantling of temporary cradles. Most
accidents happen because of:
 unsafe access to and from the cradle;

 insufficient or poorly secured counterweights and holding down systems;
 failure of the cradle platform or components such as drop nose pins and bolts;
 failure of winches, climbing devices, safety gear and ropes usually as a result of poor
maintenance; and
 failure to follow the manufacturer's instructions on erection and dismantling.
Equipment should be selected, installed, thoroughly examined and tested to ensure that it is
suitable for its intended purpose. Cradles should only be used by suitably trained and
competent workers.
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When using cradles check that:
 the cradle has adequate guard rails and toe boards and material cannot fall from or
through the cradle's base;
 the equipment is capable of fitting closely to the building and where buffers or rollers
are fitted, they will run against suitable features on the building;
 the building is capable of carrying the loads placed upon it, particularly under the
counterweights and under the fulcrum (or pivot point) of the outrigger. The advice of
a structural engineer may be needed;
 jib spacing matches the cradle length and, when the cradle can move, adequate stops
are provided to prevent the cradle running off the end of the track;
 jib length and counterweights are specified to give a factor of safety against
overturning of no less than three;
 a secondary safety rope fitted with a fall arrest device is provided and used;
 adequate operating instructions and technical support is available. If the equipment is
hired, the supplier should be able to advise;
 the cradle is not overloaded and loads are placed on the platform as uniformly as
possible;
 there is safe access into the cradle. Access at ground level is safest. If access is from
the roof, the cradle should be secured to prevent it swinging away from the building.
Access must be possible without the need to climb up or down the suspension ropes.
Also, if access is from the roof, or other raised platform, suitable means to prevent
falls from roof edges will be required (for example, guard rails and toe boards); and
 there is a plan for rescuing the operator if the crane fails while at a high level.
Even where these precautions have been taken, accidents are still possible. For example, if a
motor of a powered cradle fails, it can make the cradle tip or people may overbalance and fall
while reaching out of the cradle. Safety harnesses can save lives in these circumstances.
Harnesses should be attached to suitable anchorage points within the cradle or platform (such
as the motor mounting points) or attached to running lines rigged in the cradle. The harness
lanyards should be kept as short as possible, while allowing operators to reach their place of
work. For further advice, see section on harnesses.
It is important that a thorough visual pre-use check for obvious faults is carried out before
each use. In addition, a weekly inspection should be carried out by a competent person and a
record made of that inspection. See also the general advice about mobile and suspended
access equipment. Before taking a temporary scaffold access platform into use, the following
should be checked daily:
 The platform should be structurally sound: lift it off the ground, say
1 m, and inspect for excessive deflections;
 While it is off the ground, carry out a tactile inspection of critical connectors;
 Make sure that it runs freely up and down - try it out; and
 Check that lines of communication work properly.
At the end of the day/shift, the following at least should be done:
 the platform cleared of tools and equipment;
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 all power switched off and, where appropriate, power cables secured and made dead;
 the equipment secured where it will not be accessible to vandals or trespassers;
 notices attached to the equipment, warning that it is out of service and must not be
used; and
 shift report checked for warnings of malfunction etc.
Boatswain's chairs/seats
Boatswain's chairs and seats can be used for light, short-term work. They should only be used
where it is not practicable to provide a working platform. In general, use a chair which
consists of a seat with a back, a central suspension point and a carrying point for tools.
Whether a chair or seat is used, the user should be attached to the suspension system by a
harness and lanyard to protect against falls. See also the general advice about mobile and
suspended access equipment.
Rope access techniques
This technique can be used for inspection and some short-term light-duration construction
work. It should only be used where access from a working platform is not practicable. Check
that:
 the equipment is erected under the supervision of a competent person and then a pre-
check is carried out;
 anyone using the technique has been expertly trained and is competent;
 safe descent does not depend upon a single suspension point. Wherever possible the
main rope and safety rope should be attached to separate suspension points;
 all the equipment is checked carefully before each use and maintained to a high
standard;
 any tools which are needed for the work are attached to the operator with suitable
ropes or chains, so that they cannot be dropped; and
 where a risk of dropped tools or falling materials remains the area beneath the work
should be fenced off or protected by fans, covered walkways or similar.
Protection against falling materials
The risk of falling materials causing injury should be minimized by keeping platforms clear
of loose materials. In addition, provide a way of preventing materials or other objects rolling,
or being kicked, off the edges of platforms. This may be done with toe boards, solid barriers,
brick guards, or similar at open edges. If the scaffold is erected in a public place, nets, fans or
covered walkways may be needed to give extra protection for people who may be passing
below. High-visibility barrier netting is not suitable for use as a fall prevention device.
Checking, Corrective & Preventive Action.
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 Concerned HOD and Sectional in charge of the department shall ensure implementation
of above procedure through periodic interaction with working agency and site visit.
 Any incident/accident occurring during such working shall be communicated to Safety
Officer and persons affected should be given First Aid at nearest First Aid Station and
medical support as required.
Records
 Concerned Sectional In-charge shall maintain record of work permit for working at height
for at least one year.
 Records for incident/accident are to be maintained at the department and also made
available to Safety Department for monitoring the same at least for five years.
Attachment-1
Fall-Arrest System Checklist
Anchorage Points
1. Do workers know appropriate anchorage points for each task that requires a fall-arrest or
restraint system? ____
2. Are all anchorage points capable of supporting at least 5,000 pounds (2,268 kilograms) per
person attached?
OR is the complete fall-arrest system rated at a safety factor of at least two and supervised by
a qualified person? ____
3. Are all anchorage points for body harnesses located at shoulder height and are anchorage
points for self retracting lifeline systems located overhead? ____
4. Are anchorage points independent of the working surface? ____
5. Can a worker move from one station to another or climb up and down without exposure to
a fall? ____
6. If the lifeline, lanyard, or self-retracting lifeline is not permanently attached to an

anchorage point at the
elevated work area, is the first worker up or the last worker down protected while climbing
and traversing? ____
Vertical Lifelines
1. Does the lifeline have a minimum breaking strength of 5,000 pounds (2,268 kilograms)?
____
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2. Is the lifeline protected from abrasive or cutting edges? ____
3. Does the system provide fall protection as the worker connects to and releases from the
lifeline? ____
4. Is the lifeline arranged so workers never have to hold it for balance? ____
(A lifeline should never be used for balance.)
5. Is the vertical segment integrated with the horizontal segment to provide continuous fall
protection? ____
Horizontal Lifelines
1. Has the entire horizontal lifeline system been designed and approved by a qualified
person? ____
2. Have the anchorages to which the lifeline is attached been designed and evaluated
specifically for a horizontal lifeline? ____
3. Has the designer of the system approved the number of workers who will be using it? ____
4. Is the rope or cable free from signs of wear or abrasion? ____
5. Does the rope or cable have the required initial sag?____
6. Have the workers been warned about potential falls? ____ Have the clearances been
checked? ____
7. Is the hardware riding on the horizontal lifeline made of steel? ____ (Aluminum is not
permitted because it wears excessively.)
Fall Arresters (Rope Grabs)
1. Is the fall arrester compatible with the lifeline on which it is to be installed or operated?
____
2. Is the fall arrester in operational condition? ____
3. Is the fall arrester equipped with a changeover lever that allows it to become a stationary
anchor on the
lifeline? ____
4. Is the fall arrester equipped with a locking mechanism that prevents unintentional opening
of the
device and subsequent disengagement from the lifeline? ____
5. Is the fall arrester's “up” direction marked properly so the equipment can be attached to the
line correctly? ____
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6. Is the fall arrester included in a regular maintenance program? ____
Lanyards
1. Is the lanyard length as short as necessary and in no cases greater than 6 feet (1.8 meters)?
____
2. Are manually adjustable lanyards used when it is desirable to be able to take slack out of
the lanyard? ____
3. Does the lanyard have a shock-absorbing feature to limit the arresting forces to 500-600
pounds (227-272 kilograms)? ____
4. If the lanyard has a shock absorber, is it obvious to the user that the shock absorber has
been deployed?
____ (Is there a warning label, broken pouch, etc.?)
5. Have you prohibited tying of knots from the lanyard to the lifeline? ____ (Mechanical rope
grabs or fall arresters must be used.)
6. Are double lanyards required? _____
Retractable Lifeline (RL)
1. Are workers properly trained to use an RL? ____
2. Is the RL under a regular maintenance and inspection program? ____
3. Is the end of the cable properly spliced? ____ (thimble eye, Flemish eye-spliced, and
swaged fitting/ferrule?)
Snap Hooks
1. Have double-locking snap hooks been used? ____
2. Is the snap hook attached to the D-ring, eyebolt, or other hardware in a manner approved
by the manufacturer of the snap hook?
3. Are snap hooks inspected regularly for stress, wear, distortion, and spring failure? ____
4. Are snap hooks arranged so they are never connected to each other? ____ (They should
NOT be connected to each other.)
Body Harnesses
1. Are full-body harnesses selected for a particular job equipped with all necessary
attachment points (for fall arresting, work positioning, descent control, rescue, or ladder fall-
protection systems)? ____
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2. Are body harnesses inspected regularly for wear, abrasion, broken stitching, and missing
hardware?____
3. Is the Velcro® type of closure prohibited from all load-bearing connections? ____
4. Have workers been instructed in the use and care of body harnesses/body belts? ____
Other Considerations
1. Has the free-fall distance been considered so that a worker will not strike a lower surface
or object before the fall is arrested? _
2. Have pendulum-swing fall hazards been eliminated?____
3. Have safe methods to retrieve fallen workers been planned? ____
4. Is all of the fall-arrest equipment free of potential damage from welding, chemical
corrosion, or sandblasts? ____
5. Are all components of the system compatible according to the manufacturer's instructions?
____
6. Have employees been properly trained in the following issues? ____
– Manufacturer's recommendations, restrictions, instructions, and warnings
– Location of appropriate anchorage points and attachment techniques
– Problems associated with elongation, deceleration distance, method of use, inspection, and
storage
7. Are all regular inspections performed by trained inspectors? ____
8. Are written reports maintained? ____
Types Of Ladders
1. Step Ladders
2. Single Ladders
3. Articulated Ladders
4. Combination Ladders
5. Extension Ladders
6. Extension Trestle Ladders
7. Fixed Ladders
8. Job Made Ladders
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9. Mobile Ladder Stands
Stepladders
The Stepladder is a self-supporting portable ladder that is non-adjustable in length, with flat
steps and a hinged design for ease of storage. It is intended for use by one person.
Single Ladders
The Single Ladder is a non-self-supporting portable ladder that is non-adjustable in length,

consisting of one section. It is intended for use by one person.
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Single Ladders rated for heavy-duty or extra heavy-duty service range in length up to 30 feet
as measured along the side rail. Single Ladders rated for medium-duty service are available in
lengths up to 24 feet, and those rated for light-duty service do not exceed 16 feet in length.
Selection of proper Single Ladder size requires knowledge of the height of the top support
point. In the event the top support point is a roof eave, the top of the Single Ladder must
extend one to three feet above the roof even if the climbers’ intent is to access the roof. The
ladder must also be tied to the upper access level before climbing onto or off the ladder at the
upper level. The user must take care when getting on or off the ladder at the upper level in
order to avoid tipping the ladder over sideways or causing the ladder base to slide out.
Articulated Ladders
An Articulated Ladder is a portable ladder with one or more pairs of locking hinges which
allow the ladder to be set up in several configurations such as a single or extension ladder,
with or without a stand-off, a stepladder, a trestle ladder, scaffold or work table. Each pair of
articulated joints in the ladder
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can be locked in one or more positions to accommodate the various configurations. The
locking positions of the hinges allow set-up at the proper angles to accommodate each
configuration that the manufacturer has designated.
An instruction label appears on each Articulated Ladder illustrating the locking hinges in
both the locked and unlocked positions. Each Articulated Ladder manufacturer has a unique
locking hinge design and each lock must visibly indicate whether it is locked or unlocked. As
a result, it is important that the user become familiar with the proper operation of the hinge
and make sure all the hinges are locked before using the ladder. Never attempt unlocking or
repositioning any of the hinges while standing on the ladder.
The hinges of an Articulated Ladder require periodic lubrication. The hinges should be
lubricated upon receipt of the ladder and then annually or more frequently, depending upon
use. When involved in messy work, place a covering over the exposed hinge mechanisms to
avoid getting contaminants into them that may cause malfunctions.
Combination Ladders
A Combination Ladder is a portable ladder capable of being used as Stepladder, or as a

Single or Extension Ladder. It may also be capable of being used as a Trestle Ladder or as a
Stairwell Ladder. Its components may be used as Single Ladders. This type of ladder can be
designed with either steps or rungs, and the inclusion of a pail shelf is optional. When steps
are present, the ladder should be erected so that the step surfaces are horizontal. Either
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spreaders or a locking device can be used to securely hold the front and rear sections in the
open position.
An instruction label appears on each Combination Ladder to either illustrate the locking
mechanism, provide instructions for the locking mechanism, or both. It is important that the
user become familiar with the proper operation of the locking mechanism and make sure all
the joints are locked before using the ladder. Never attempt unlocking or repositioning any of
the joints while standing on the ladder.
Another on-product label illustrates all the acceptable uses and positions for a given
Combination Ladder. Configurations not illustrated on the label are not to be used.
The size of a Combination Ladder, when used in the Stepladder configuration, ranges from 4
feet to a maximum of 10 feet, as measured along the front side rail from the bottom of the
foot to the top of the top cap or to the top of the top step when no top cap is used. The
maximum Extension Ladder length is marked on the identification label.
Extension Ladders
The Extension Ladder is a non-self-supporting portable ladder that is adjustable in length. It

consists of two or more sections that travel in guides or brackets so arranged so as to permit
length adjustment. It is intended for use by one person.
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Extension Ladders are built with either two or three adjustable telescopic sections. The
maximum extended length is dependant upon the number of sections as well as the duty
rating of the ladder as follows:
Duty Rating Type Two-Section (feet) Three-Section (feet)

Extra heavy duty Type 1A 60 72
Heavy duty Type I 60 72
Medium duty Type II 48 60
Light duty Type III 32 --
Selection of proper Extension Ladder size requires knowledge of the height of the top support
point. In the event the top support point is a roof eave, the top of the Extension Ladder must
extend one to three feet above the roof eave if the climbers’ intent is to access the roof. The
ladder must also be tied to the upper access level before climbing onto or off the ladder at the
upper level. The user must take care when getting on or off the ladder at the upper level in
order to avoid tipping the ladder over sideways or causing the ladder base to slide out
Extension Trestle Ladders
The Extension Trestle Ladder is a self-supporting portable ladder that is adjustable in length,
consisting of a Trestle Ladder base and a vertically adjustable Extension section with a means
for locking the ladders together. It is intended for use by one person.
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An Extension Trestle Ladder base section ranges in length up to 20 feet as measured along
the side rail. The Extension section length may not exceed the base section length. The
highest standing level on an Extension Trestle Ladder is the second step below the top of the
extension section, or slightly more than 2 ft from the top of the ladder. The highest standing
level is required to be marked on the specifications label on the side rail. Therefore, when
planning your job, the maximum work height is established by adding the user’s height and
reach to the highest standing level.
Fixed Ladders
A Fixed Ladder is a non-self-supporting ladder that is non-adjustable in length and

permanently attached to a structure at a Pitch ranging from 60 degrees to 90 degrees from the
horizontal. The Preferred Pitch of a Fixed Ladder is between 75 degrees and 90 degrees from
the horizontal. A Fixed Ladder is considered to be of “Substandard Pitch” if it is installed at
an angle between 60 degrees and 75 degrees from the horizontal. Fixed Ladders having a
Pitch greater than 90 degrees are not allowed.
Job Made Wooden Ladders

Job-make wooden ladders are custom-made to fit specific job situations during construction
or demolition operations. Their primary purpose is to provide access to or egress from a work
area. They are not intended to serve as a workstation. They are temporary in nature and serve
only until a particular phase of work is completed or until permanent stairways or Fixed
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Ladders are ready for use (see Fig. 1). They are not to exceed 24-feet in working length. In
the event the required ladder length exceeds 24-feet, then two or more separate Job-Made
Ladders are to be used in conjunction with platforms that are protected with railings.
Mobile Ladder Stand and Mobile Ladder Stand Platforms
A Mobile Ladder Stand (Fig. 1) is a movable, fixed height, self-supporting ladder consisting
of wide flat treads in the form of steps which give access to a Top Step. The assembly may
include handrails and is intended for use by one person. See Fig. 3 for additional examples of
Mobile Ladder Stands.
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A Mobile Ladder Stand Platform (Fig. 2) is a movable, fixed height, self-supporting unit
having one or more standing levels and is provided with a means of access or egress to the
platform or platforms. The assembly may include handrails and/or guardrails, and may be
designed to accommodate one or more persons. See Fig. 4 for additional examples of Mobile
Ladder Stand Platforms.
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Requirements for all Mobile Ladder Stands and Platforms
The structural Safety Factor for this class of products is 4. In other words, the units must be
capable of supporting 4 times their Rated Load.
All threaded fasteners used in the construction of Mobile Ladder Stands and Platforms must
be of a self-locking type.
All exposed surfaces must be free of sharp edges and burrs.
Scaffold
Associated Hazards:Use of unsuitable or faulty materials, Inadequate supported scaffold

board, Inadequate or Irregular Platform Width, Omission of Guard Rails or Toe Boards,
Failure to Secure Scaffolds, Faulty Alterations without Approval, Unsecured Ladder Slip,
Misuse of couplers, Overloading of Platforms and Scaffolds, Unsecured Ladder Slip, Fire due
to Welding / Gas Cutting in Wood Scaffold, Falling Object, Falling of Person, Protruding
Nail Injuries, Hit by Exposed parts of Scaffolds, over head electric lines etc.
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Competent person -one who is capable of identifying existing and predictable hazards in the
surroundings or working conditions which are unsanitary, hazardous, or dangerous to
employees, and who has authorization to take prompt, corrective measures to eliminate them.
Qualified person -one who, by possession of a recognized degree, certificate, or professional

standing, or who by extensive knowledge, training, and experience, has successfully
demonstrated his or her ability to solve or resolve problems related to the subject matter, the
work, or the project.
Erection and Dismantling
 Scaffolds are intended to provide safe working positions at elevations. To

eliminate fall exposures, scaffolds must have complete handrails, mid rails, and
decking that eliminate the need for fall-arrest equipment. Do not use fall arrest
equipment as a substitute for handrails, mid rails, or a complete deck.
 The total load on a scaffold consists of the sum of the weight of the workers and
materials on a scaffold plus the weight of the scaffold. Scaffolds and their
components must be capable of supporting, without failure, at least four times the
maximum intended load.
 No scaffold shall be erected or be substantially or altered or be dismantled except
under the immediate supervision of a responsible person.
 All material for any scaffold shall be inspected by a competent person on each
occasion before being taken into use. Contractors shall appoint such competent
persons and shall arrange for their training as necessary.
General Safety Requirements
• The use of barrels, boxes, loose tile blocks or other unsuitable objects as supports for
working platforms shall not be permitted.
• Every scaffold shall be securely supported or suspended and shall, where necessary, be
sufficiently and properly strutted or braced to ensure stability. The use of braces or
framework as means of access to the working surface shall not be permitted.
• Every platform, gangway, run or stairs shall be kept free from any unnecessary obstruction,
material, rubbish and projecting rails, when they become slippery, appropriate steps shall be
taken by way of sanding, cleaning or otherwise to remedy the defect.
• Each supporting member used in the construction of runways, platforms, ramps and
scaffolds shall be securely fastened and braced. The supporting member shall be placed on a
firm, rigid, smooth foundation of a nature that will prevent lateral displacement.
• Where planks are butt-jointed, two parallel putlogs shall be used, not more than 100 mm
apart, giving each plank sufficient support. Nails shall penetrate to the holding piece to a
depth of at least 12 times the diameter of the nail.
• A scaffold platform plank shall not project beyond its end supports to a distance exceeding
four time the thickness of the plank unless it is effectively secured to prevent tipping.
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Cantilever of scaffold planks shall be avoided. Ledgers or putlog should be erected to support
the ends of such planks.
• All scaffolds or working platforms of any nature shall be securely fastened to the building
or structure; if independent of the building, they shall be braced or guyed properly.
• Grease, mud, paint gravel or plaster or any such hazardous substances shall be removed
from scaffolds immediately. To prevent slipping on the platforms, either sand or saw dust or
other suitable material shall be spread.
• Men shall not be allowed to work from scaffolds during storms or high winds.
• In case both light and heavy duty scaffolds are used in close vicinity, conspicuously placed
notice boards shall indicate the light duty scaffolds and the limits on their usages.
Electrical Hazards
• Care shall be taken to see that no un-insulated electric wire exists within 3 m of the working
platform, gangways, runs, etc., of the scaffold.
• While carrying bars, rods or pipes of any kind conducting material of length greater than 3
m, in the vicinity of electric wires, special care shall be taken that these do not touch the
electric wires.
Mechanical and Traffic Hazards
• Care shall be taken to see that no part of a scaffold is struck by a truck or other heavy
moving equipment and no material shall be dumped against it.
• Scaffolds on thorough fares shall be provided with warning lights, if general lighting is not
sufficient to make it clearly visible.
• Access to fire alarms, cable tunnels, hydrants, etc., shall remain free at all times. Care
should be taken for underground cables and equipment when parts of scaffolds or other
fasteners have to be driven in the ground.
Opening
There is no opening in any working platform except for allowing access to such working
platform.
CONSTRUCTION AND MATERIAL
Every scaffold and every part thereof shall be of good construction, of suitable and sound
material and of adequate strength for the purpose for which it is used. The Contractor/Sub-
contractor shall be responsible for the design and safety of scaffold system. Metal scaffolds
shall conform to IS: 2750-1964!
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Cat ladder
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MEANS OF ACCESS
There shall be suitable and sufficient safe access to and egress from every place at which any
person at any time works. A safe and convenient means of access should be provided to all
platform level of scaffolds. Means of access may consist of
 Ladder
 Ramp
 Stairway
Ladder
Portable ladders are not recommended for flights above 4 m. They should be placed at an
angle of approximately 750 from the horizontal. Both top and bottom should be secured to
prevent displacement, and the ladder rails should be extended at least 1 m above the top
landing. Fixed ladders should be provided for flights above 4 m. Fixed ladder should have
landings of minimum 600 mm extent at intervals not greater than 6.0 m. The width of ladder
shall not be less than 300 mm. All the ladders used for access to scaffolds should conform to
the requirement of IS : 3696 (Part-2) - 1996*.
STANDARDS OR UPRIGHTS, LEDGERS AND PUTLOGS
Standards or uprights of scaffolds shall –
• The foot or base of any standard or upright shall be placed on an adequate base plate in a
manner to prevent tripping or sinking or its displacement shall be prevented in some other
sufficient way.
• Timber sole plates of at least 210 mm width and 25 mm thickness should be laid to support
the base plate for standards. The sole plate area should be not less than 1000 sq. cm or for
soft material 1700 sq. cm.
• Ledgers shall be securely fastened to the uprights by efficient means e. g. right angle
couplers.
• The distance between two consecutive putlogs and transoms or other types of supports on
which a platform rests shall be fixed with due regard to the anticipated load and the nature of
the platform flooring. The distance with single planking shall not, as a general rule, exceed 1
m with planks of 32 mm in thickness, 1.5 m with planks of 38 mm in thickness; 2.6 m with
planks of 50 mm in thickness.
STABILITY OF SCAFFOLDS
• Every scaffold shall :
o be securely supported or suspended;
o where necessary be sufficiently and properly strutted or braced to prevent collapse;

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o be rigidly connected with the building or other structure unless the scaffold is so designed
and constructed as to ensure stability without such connection.
• Every structure and appliance used as a support for a scaffold shall –
o have a firm footing or be firmly supported, where necessary be sufficiently and properly
strutted or braced to prevent collapse and to ensure stability.
o Every scaffold which can be moved on wheels or skids (not being a suspended scaffold or
slung scaffold) shall be –
o constructed with due regard to the stability and if necessary, for stability, be adequately
weighted at the base.
o Use only on a firm and even surface not slopping as involve risk of instability of the
scaffold
o adequately secured to prevent movement when any person is working upon it or upon any
ladder or other plant or equipment, being a ladder, plant or equipment which is supported by
the scaffold; and
o moved only by application of force at or near the base.
o Loose bricks, drain pipes, or other unsuitable material shall not be used for support of
scaffolds.
LADDERS USED AS UPRIGHTS IN SCAFFOLDS
• Ladder scaffolds shall be used only if the work is of such a light nature and the material
required for the work is such that this type of scaffold can be used safely
• Ladders serving as uprights in Scaffolds
o be of adequate strength;
o be placed so that the two stiles or sides of each ladder are evenly supported or suspended:
and
o be secured to prevent slipping.
CONSTRUCTION OF WORKING PLATFORM, GANGWAYS AND RUNS
Every working platform, gangway and run from any part of which a person is liable to fall a
distance of more than 2 m and being struck by materials falling through the platform shall be
• closely boarded, planked or plated; and
• secured so that the gap between adjacent boards, planks or plates does not exceed 25 mm
• No gangway or run with the slope, exceeding vertical to 1.5 horizontal shall be used.
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• Gangways or runs must be fitted with stepping laths if the surface is slippery or if the slope
is steeper.
• Corrugated sheets may be used as platform, gangway and runs provided they are designed
for strength and stability, fixed properly and made up of good quality material.
Required Fall Protection System for Various Types of Scaffolds
Type of Scaffold Fall Protection required
Aerial lifts Personal fall-arrest system
Boatswains’ chair Personal fall-arrest system
Catenary scaffold Personal fall-arrest system
Crawling board (chicken Personal fall-arrest system, or a guardrail system, or a ¾ inch

ladder) (1.9 cm) diameter grab line or equivalent handhold securely
fastened beside each crawling board
Float Scaffold Personal fall-arrest system
Ladder jack scaffold Personal fall-arrest system
Needle beam scaffold Personal fall-arrest system
Self-contained scaffold Both a personal fall-arrest system and a guardrail system
Single-point and two-point Both a personal fall-arrest system and a guardrail system
suspension scaffold
Supported scaffold Personal fall-arrest system or guardrail system
All other scaffolds not Personal fall-arrest system and a guardrail system that meet
specified above the required criteria
BOARDS AND PLANKS IN WORKING PLATFORMS, GANGWAYS AND RUNS
• Every board or plank forming part of a working platform, gangway or run shall –
o afford adequate security having regard to the distance between putlog and other supports;
o be not loss than 200 mm wide and 50 mm thick;
o not project beyond its end support by more than 4 times the thickness of the board unless it
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is effectively secured to prevent tipping;
o be provided with adequate beveled pieces to minimize tipping.
• Every board or plank shall
o rest securely and evenly on its supports;
o have at least 3 supports unless it is strong and thick enough not to have excessive sagging.
• Working platforms shall extend, wherever practicable, at least 600 mm beyond the end wall
or working face where work is to be carried out.
WIDTH OF WORKING PLATFORM
Every working platform from which a person is liable to fall a distance of more than 2 meter
shall
o be 600 mm wide when used for persons only and not for materials;
o be 800 mm wide when used for persons and for the deposit of materials. There must be 430
mm passage left for persons. If wheel barrows are to be used, the passage must be increased
to 600 mm.
• 430 mm wide platforms are, however, permitted on ladder scaffolds, folding trestle
scaffolds, slung scaffolds in the vicinity of a roof and suspended scaffolds when the work is
light and of short duration.
• The space between the edge of the working platform and the face of the building shall be as
small as practicable. Where workmen sit on the edge of the platform to do their work, a space
not exceeding 300 mm shall be permitted.
WIDTH OF GANGWAY AND RUNS
Every gangway or run shall :
o be 430 mm in wide if used for the passage of persons only;
o be 600 mm wide if used for passage of materials.
GUARD RAILS AND TOE BOARDS For Working Platforms, Gangways, Stairs, Runs
• Every side of a working platform (more than 2 m), Gangways, Stairs, Runs shall be
provided with:
o Guard rail to a height of 1.15 m above the platform or place.
o toe board of at least 100 mm high.
o an intermediate guard rail at not more than 765 mm height.
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• Guard rails and toe boards may be removed for access purposes, but must be replaced as
soon as possible afterwards.
PLATFORM, GANGWAYS, RUNS AND STAIRS, ETC. TO AFFORD SAFE

FOOTHOLD
All platforms, gangways, runs or stairs shall be –
• Free from slippery conditions by non-skid board / gratings etc.
• Kept free from all rubbish and projecting nails.
PROTECTION FROM FALLING MATERIAL
• At any place on the site of the operations or works or adjoining streets, pedestrian way or place
where any person including public, is employed or otherwise moving, preventive steps shall be
taken to protect persons from being struck by any falling material or article.
• Scaffold materials, tools or other objects and materials including waste material shall not be
thrown, tipped or shot down from a height where they are liable to cause injury. The material
shall be lowered down.
PROJECTING NAILS AND LOOSE MATERIALS
• No material with projecting nails shall be used in any work or allowed to remain in place.
They are a source of danger to persons employed.
LOADS ON SCAFFOLDS
• A scaffold shall not be overloaded and the load shall be evenly distributed.
• Material or loads shall be moved or deposited without imposing any violent shock.
• Material shall not be kept upon a scaffold unless needed for work within a reasonable time.
AVOIDANCE OF DANGER FROM COLLAPSE OF STRUCTURE
• All practicable precautions shall be taken by the use of temporary guys, stays, supports and
fixings where necessary to prevent danger to any person employed or public through the
collapse of any part of a building or other structure during any state of weakness or instability.
• Where any work is done which may affect the foundations or the stability of an adjacent
structure, shoring or other safeguards shall be provided. Safety Measures
• Scaffolds must always be erected maintained and dismantled by competent and trained
workmen.
• Scaffold must be properly braced and when necessary tied into building or the structure.
Platform must be properly supported and span of planks should not be too great. They should
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not be overloaded.
• Guard rails and toe boards must always be fitted and be maintained in position.
• Loose packaging such as bricks should never be used below standards. Standards should be
vertical and if of metal, should be mounted on steel base plates.
• Ledgers should be horizontal and always be connected to the standards by load bearing
lashings, if not timber or by right angle load bearing couplers if of metal.
• Transoms and Putlog should be horizontal and at right angle to tile ledgers, to which they
should be secured by right angle couplers or Putlog couplers.
• Platform should be closed boarded, overlapping of boards and excessive overhangs should be
avoided.
• Diagonal bracing parallel to the face of the building and full height of the scaffold should be
provided at 3.0 m intervals
SLOPING ROOF
• The roof or part of roof having a pitch of more than 10 degrees which is in the course of
construction, maintenance, repair demolition or used as access or egress shall be provided with
standard guard-rail and toe-board at any point where a person can fall.
• Where the pitch is more than 30 degrees or the condition of the surface slippery, crawling
ladders or boards shall be provided and used for work or from sloping roofing or when used as
access.
• a barrier shall be provided at the lower edge of the sloping roof or the work shall be done from
a securely supported working platform, at least 430 mm wide with guard-rails and toe-boards.
• Full edge protection at eaves level will normally be required for work on sloping roofs. The
edge protection needs to be strong enough to withstand a person falling against it. The longer
the slope and the steeper the pitch the stronger the edge protection needs to be. A properly
designed and installed independent scaffold platform at eaves level will usually be enough. Less
substantial scaffolding barriers (rather than platforms) may not be strong enough for work on
larger or steeper roofs, especially slopes in excess of 30o.
• On some larger roofs, the consequences of sliding down the whole roof and hitting the eaves
edge protection may be such that intermediate platforms at the work site are needed to prevent
this happening.
• If the work requires access within 2 m of gable ends, edge protection will be needed there as
well as at the eaves.
• Powered access platforms can provide good access as an alternative to fixed edge protection.
They can be particularly useful in short-duration work (see ‘Short-duration work on sloping
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roofs’) and during demolition when gaps are created in the roof.
• Crawling ladders or boards shall be –
o of good construction;
o of sound material and properly maintained;
o properly supported;
o securely fixed or anchored to the sloping surface, over the ridge, etc. to prevent slipping.
CLASSIFICATION OF SCAFFOLDS BY TYPE
• Independent Scaffolding / Double Pole : Scaffolding consists of two rows of vertical members
connected in both direction making a frame work.
• Connected scaffolding / Single Pole : The consists single row of vertical and horizontal
members connected with existing structure by means of put log / cross members .
• Mild Steel, Tubular / Structural Scaffolding : This type is designed as modular system for
sturdy and repetitive usage.
• Suspended Scaffolds
SLUNG / HANGING / SWING / CONTINUOUS SCAFFOLDS
• No chain, wire rope, lifting gear, metal tube or other means of suspension for slung scaffolds
shall be used unless the following requirements are observed.
o It is suitable and of adequate strength for the purpose for which it is used. The wire rope shall
not be less than ¾ inch dia.
o It is properly and securely fastened to safe anchorage points and to the scaffold lodgers or
other main supporting members;
o It is so placed as to ensure stability of the scaffold;
o It is as nearly vertical as is reasonably practicable: and
• No rope other than a wire rope shall be used for the suspension of slung scaffold
• Where chains or wire ropes are used for the suspension of a slung scaffold, steps shall be taken
to prevent such chains or wire ropes coming into contact at points of suspension with edges
where this would cause danger.
• Every slung scaffold shall be secured to prevent undue horizontal movement while it is used as
a working platform.
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• The platform shall be close-boarded and evenly set with each board adequately supported.
• The framework for the platform shall be constructed from ledgers and transoms fixed by right
angle couplers. The working platform shall be sufficiently wide and provided with hand rails of
1.05 meters height with 1 top rail, mid rail and toe board of minimum10 cm high.
• If the platform is long and provided with two lifting arrangements, lowering / lifting of the
scaffolding should be done simultaneously at both the ends. A safety rope shall be provided in
addition to the main supporting rope.
CANTILEVER, JIB, FIGURE AND BRACKET SCAFFOLDS
• No cantilever scaffold or jib scaffold shall be used unless it is adequately supported, fixed and
anchored, has outriggers of adequate length and strength and is where necessary sufficiently and
properly strutted or braced to ensure rigidly and stability.
STEEL/PIPE SCAFFOLDS
Material
• Steel tubes for individual component types scaffolding shall be of heavy class welded for
seamless tubes of 40 mm nominal bore and of grade not less than YST 22 of IS:1161 - 1968
‘Specification for Steel Tubes for Structural Purposes (Second Revision). For other types of
scaffolding, the individual tube or tubes forming part of the unit frame shall conform to the
requirements of IS:1161:1968.
Design
• The design of Steel Scaffold and all its components shall conform to IS:2750:1964 (re-affirm
: 1995).
• The base plate shall have a level surface area of at least 15 cm x 15 cm or equivalent area,
concentric with the axis of the shank to which it shall be securely attached.
• Before starting the scaffolding erection, the surface on which it has to be erected must be made
firm and level.
• Once the surface is ready, sole plates have to be kept. It can be a timber sleeper or steel plate.
Sole plates should be long enough to hold at least two vertical pipes and should extend 600 mm
beyond the vertical pipes. Sole plates may be avoided in case if the scaffold is erected on a firm
ground like concrete floor.
• However, base plates are a must, irrespective of where the scaffolding is erected. It should be
10 x 150 x 150 mm steel plate. Sole plates and base plates support the entire load of the
scaffolding. They distribute the load and prevent the scaffold from sinking.
• Verticals should not be kept more than 3 M apart. Weld zones of scaffolding frame component
should be checked against crack before using for erection.
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• Do not use pipes which are (a) split along their length, (b) bent or kinked, (c) thin at the ends,
(d) heavily pitted and (e) having badly cut or ragged ends.
• Do not use corroded or deformed couplers and make sure that the threads are in good
condition.
• Allowable maximum span between supports for o A - 1.5” thick plank is 1.5 M and o B - 2.0”
thick plank is 2.6 M
• The overhang of a scaffold plank should be at least 50 mm but not more than 4 times board
thickness.
• Knots or knot holes in the scaffolding board should not exceed 2” in diameter across the edge.
The board must not be split even partway. The grain should be reasonably straight.
• No Dropping or throwing materials from the top shall be allowed. A rope should be used for
this.
SUSPENDED SCAFFOLDS
• Every suspended scaffold shall be provided with adequate and suitable chains or ropes and
winches or other lifting appliances or similar devices and shall be suspended from suitable
outriggers, joists, run-ways, rail tracks or other equally safe anchorage.
• The winches or other lifting appliances or similar devices of a suspended scaffold shall be
o provided with a brake or similar devices which comes into operation when the operating
handle or lever is released; and
o adequately protected against the effects of weather, dust or material likely to cause damage.
• The outriggers for a suspended scaffold shall be –
o of adequate length and strength and properly installed and supported;
o installed horizontally and provided with adequate stops at their outer ends;
o properly spaced having regard to the construction of the scaffold and of the runway, joist or
rail track on which the scaffold is carried.
• Where counterweights are used with outriggers, these counterweights shall be securely
attached to the outriggers and shall be not less than three times weight which would counter-
balance the weight suspended from the outrigger including the weight of the runway, joist or rail
track, the suspended scaffold and persons and other load thereon.
• the points of suspension of every suspended scaffold shall be at an adequate horizontal

distance from the face of the building or other structures.
• Every runway, joist and rail track supporting suspended scaffold shall be –
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o of suitable and sound material;
o of adequate strength for the purpose for which it is used;
o free from patent defect;
o provided with adequate stops at each end.
• The suspension ropes or chains of a suspended scaffold shall be –
o securely attached to the outriggers or other supports and to the platform framework or to any
lifting appliance or other device attached thereto, as the case may be; and
o kept in tension.
• Where winches are used with suspended scaffolds the suspension ropes shall be of such a
length that the lowest position at which the scaffold is intended to be used, there are not less
than two turns of rope remaining on each winch drum and the length of each rope shall be
clearly marked on its winch.
• Every part of a suspended scaffold and all plant and equipment used for the purpose shall be –
o of good construction;
o suitable and sound material;
o properly maintained;
o where constructed of metal, free from corrosion.
• Adequate arrangements shall be made to prevent undue tipping, tilting and swinging of a
suspended scaffold and to secure it to prevent undue horizontal movement while it is being used
as a working platform.
• No rope other than a wire rope shall be used.
• Fiber rope and pulley block may be carried out may be used provided, the work to be carried
out from a suspended scaffold is of such a light nature and the material required for the work is
such that a cradle or similar light weight suspended scaffold having a platform of not less than
430 mm wide.
• If a suspended scaffold is carried on fiber ropes and pulley blocks, the rope shall be spaced not
more than 3.20 m apart. • The platform of every suspended scaffold shall be :
o closely boarded, planked or plated; and
o of adequate width to afford adequate working space at every working point and shall, in any
event
be at least 600 mm wide if used as a footing only and not for the deposit of any material;
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be at least 800 mm wide if used for the men and deposit of material.
be acceptable to 430 mm wide if it is cradle of light weight.
not to be used for the support of any higher scaffold.
o so arranged or secured that at each working position the space between the face of the
building or structure and the platform is as small as reasonably practicable;
BOATSWAIN'S CHAIRS, CAGES, SKIPS, ETC. (NOT POWER OPERATED)
• No Boatswain's Chair, cage, skip or similar plant or equipment, not power driven appliance,
shall be used unless
o it is of good construction, suitable and sound material, adequate strength, free from patent
defects and properly maintained.
o the outriggers or other supports are of adequate strength and properly installed and supported;
o chairs, ropes and lifting gear are firmly secured to the outriggers and to the chair, skip, etc.
o suitable means are provided to prevent any occupant falling out.
o it is free of materials or articles liable to interfere with the Occupant's handhold or foothold or
otherwise endanger him. o suitable measures are taken to prevent spinning or tipping in a
manner dangerous to any occupant.
o in the case of any skip or other receptacle it is at least 0.91 m to 1.15 m deep.
o its installation has been and its use is, supervised by a competent person.
• Boatswain's chair, cage, skip or similar plant or equipment not power operated, shall be used
as a working place only when the work would not take long enough to make use of a suspended
scaffold reasonably practicable.
TRESTLE SCAFFOLD OR MOBILE SCAFFOLD
• All trestles and supports used for the construction of any trestle scaffold shall be –
o of good construction, suitable and sound material;
o of adequate strength for the purpose for which they are used and free from patent defects.
o properly maintained.
• A trestle scaffold shall not be used
o if the scaffold is so situated that a person would be liable to fall from its working platform a
distance of more than 4.5 m; or
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o if constructed with more than one tier where folding supports are used.
• No trestle scaffold shall be erected on a scaffold platform unless
o the width of the said platform is such as to leave sufficient clear space for the transport of
material along the platform; and
o the trestles or supports are firmly attached to the platform and adequately braced to prevent
displacement.
• Inspection of Scaffolds, Boatswain's Chair etc.
• No scaffold, or Boatswain's chair, etc. shall be used unless –
o it has been inspected during the previous 7 days by a competent person;
o it has been inspected after a rough weather conditions likely to have affected its strength or
stability or to have displaced any part.
o the details of each inspection are recorded. Records are not required for scaffolds under 2 m in
height or for ladder or trestle scaffolds.
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Job Hazard Analysis
What is a job hazard analysis?
A job hazard analysis is a technique that focuses on job tasks as a way to identify hazards
before they occur. It focuses on the relationship between the worker, the task, the tools, and
the work environment. Ideally, after you identify uncontrolled hazards, you will take steps to
eliminate or reduce them to an acceptable risk level.
Why is job hazard analysis important?
Many workers are injured and killed at the workplaceevery day in the United States. Safety
and health can addvalue to your business, your job, and your life. You can helpprevent
workplace injuries and illnesses by looking at yourworkplace operations, establishing proper
job procedures,and ensuring that all employees are trained properly.One of the best ways to
determine and establish properwork procedures is to conduct a job hazard analysis. A
jobhazard analysis is one component of the larger commitmentof a safety and health
management system.
What is the value of a job hazard analysis?
Supervisors can use the findings of a job hazard analysisto eliminate and prevent hazards in
their workplaces.This is likely to result in fewer worker injuries and illnesses, safer, more
effective work methods; reduced workers’compensation costs; and increased worker
productivity.
The analysis also can be a valuable tool for training newemployees in the steps required to
perform their jobs safely.For a job hazard analysis to be effective, management must
demonstrate its commitment to safety and health and follow through to correct any
uncontrolled hazards identified.
Otherwise, management will lose credibility and employees may hesitate to go to
management when dangerous conditions threaten them.
What jobs are appropriate for a job hazard analysis?
A job hazard analysis can be conducted on many jobs in your workplace. Priority should go
to the following types of jobs:
• Jobs with the highest injury or illness rates;

• Jobs with the potential to cause severe or disabling injuries or illness, even if there is no
history of previous accidents;
• Jobs in which one simple human error could lead to a severe accident or injury;
• Jobs that are new to your operation or have undergone changes in processes and procedures;
and
• Jobs complex enough to require written instructions.
Where do I begin?
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1. Involve your employees. It is very important to involve your employees in the hazard
analysis process.
They have a unique understanding of the job, and thisknowledge is invaluable for finding
hazards. Involvingemployees will help minimize oversights, ensure aquality analysis, and get
workers to “buy in” to thesolutions because they will share ownership in theirsafety and
health program.
2. Review your accident history.Review with youremployees your worksite’s history of

accidents andoccupational illnesses that needed treatment, lossesthat required repair or
replacement, and any “near
misses” —events in which an accident or loss did notoccur,but could have. These events are
indicators that theexisting hazard controls (if any) may not be adequateand deserve more
scrutiny.
3. Conduct a preliminary job review.Discuss withyour employees the hazards they know
exist in theircurrent work and surroundings. Brainstorm with themfor ideas to eliminate or
control those hazards.
If any hazards exist that pose an immediate dangerto an employee’s life or health, take
immediateaction to protect the worker. Any problems that canbe corrected easily should be
corrected as soon aspossible. Do not wait to complete your job hazard analysis.This will
demonstrate your commitment to safety andhealth and enable you to focus on the hazards
andjobs that need more study because of their complexity.For those hazards determined to
present unacceptablerisks, evaluate types of hazard controls.
4. List, rank, and set priorities for hazardous jobs.List jobs with hazards that present
unacceptable risks,based on those most likely to occur and with the mostsevere
consequences. These jobs should be your firstpriority for analysis.
5. Outline the steps or tasks. Nearly every job can bebroken down into job tasks or steps.
When beginninga job hazard analysis, watch the employee perform thejob and list each step
as the worker takes it. Be sureto record enough information to describe each jobaction
without getting overly detailed. Avoid makingthe breakdown of steps so detailed that it
becomesunnecessarily long or so broad that it does not includebasic steps. You may find it
valuable to get input fromother workers who have performed the same job.Later, review the
job steps with the employee to makesure you have not omitted something. Point out thatyou
are evaluating the job itself, not the employee’s jobperformance. Include the employee in all
phases ofthe analysis—from reviewing the job steps andprocedures to discussing
uncontrolled hazards andrecommended solutions.Sometimes, in conducting a job hazard
analysis,
it may be helpful to photograph or videotape theworker performing the job. These visual
records can
be handy references when doing a more detailedanalysis of the work.
How do I identify workplace hazards?
A job hazard analysis is an exercise in detective work. Yourgoal is to discover the following:
• What can go wrong?
• What are the consequences?
• How could it arise?
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• What are other contributing factors?

• How likely is it that the hazard will occur?
To make your job hazard analysis useful, documentthe answers to these questions in a
consistent manner.
Describing a hazard in this way helps to ensure that yourefforts to eliminate the hazard and
implement hazard controlshelp target the most important contributors to the hazard.
Good hazard scenarios describe:

• Where it is happening (environment),
• Who or what it is happening to (exposure),
• What precipitates the hazard (trigger)
• The outcome that would occur should it happen(consequence), and
• Any other contributing factors.
A sample form found in Appendix 3 helps you organizeyour information to provide these
details.
Rarely is a hazard a simple case of one singular causeresulting in one singular effect. More
frequently, manycontributing factors tend to line up in a certain way to createthe hazard. Here
is an example of a hazard scenario:
In the metal shop (environment), while clearing asnag (trigger), a worker’s hand (exposure)
comesinto contact with a rotating pulley. It pulls hishand into the machine and severs his
fingers(consequences) quickly.To perform a job hazard analysis, you would ask:
What can go wrong?

The worker’s hand could comeinto contact with a rotating object that “catches” it andpulls it
into the machine.
What are the consequences?

The worker couldreceive a severe injury and lose fingers and hands.
How could it happen?

The accident could happen asa result of the worker trying to clear a snag duringoperations or
as part of a maintenance activity while thepulley is operating. Obviously, this hazard
scenariocould not occurif the pulley is not rotating.
What are other contributing factors?

This hazardoccurs very quickly. It does not give the worker muchopportunity to recover or
prevent it once his hand comesinto contact with the pulley. This is an important
factor,because it helps you determine the severity andlikelihood of an accident when
selecting appropriatehazard controls. Unfortunately, experience has shownthat training is not
very effective in hazard control whentriggering events happen quickly because humans
canreact only so quickly.
How likely is it that the hazard will occur?

Thisdetermination requires some judgment. If there havebeen “near-misses” or actual cases,
then the likelihoodof a recurrence would be considered high. If thepulley is exposed and
easily accessible, that also is aconsideration. In the example, the likelihood that thehazard
will occur is high because there is no guardpreventing contact, and the operation is
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performedwhile the machine is running. By following the stepsin this example, you can
organize your hazardanalysis activities.
The examples that follow show how a job hazard analysiscan be used to identify the existing
or potential hazards foreach basic step involved in grinding iron castings.
Grinding Iron Castings: Job Steps
Step 1. Reach into metal box to right of machine,grasp casting, and carry to wheel.
Step 2. Push casting against wheel to grind off burr.
Step 3. Place finished casting in box to left of machine.
Example Job Hazard Analysis Form
Job Location: Analyst: Date:Metal Shop Joe Safety
Task Description
Worker reaches into metal box to theright of the machine, grasps a 15-pound casting
andcarries it to grinding wheel. Worker grinds 20 to 30castings per hour.
Hazard Description
Picking up a casting, the employeecould drop it onto his foot. The casting’s weight and
heightcould seriously injure the worker’s foot or toes.
Hazard Controls
1. Remove castings from the box and place them on atable next to the grinder.
2. Wear steel-toe shoes with arch protection.
3. Change protective gloves that allow a better grip.
Use a device to pick up castings
Twenty-four states and two territories operate theirown OSHA-approved safety and health
programs and mayhave standards that differ slightly from federal requirements.Employers in
those states should check with the appropriatestate agency for more information.
Why should I review my job hazard analysis?
Periodically reviewing your job hazard analysis ensuresthat it remains current and continues
to help reduceworkplace accidents and injuries. Even if the job has notchanged, it is possible
that during the review process you willidentify hazards that were not identified in the initial
analysis.It is particularly important to review your job hazardanalysis if an illness or injury
occurs on a specific job.Based on the circumstances, you may determine that youneed to
change the job procedure to prevent similar incidentsin the future. If an employee’s failure to
follow proper jobprocedures results in a “close call,” discuss the situationwith all employees
who perform the job and remind themof proper procedures. Any time you revise a job
hazardanalysis, it is important to train all employees affected bythe changes in the new job
methods, procedures, orprotective measures adopted.
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Machinery safety
Machinery risk assessment
Crushing
Where a part (or whole of) the body is crushed between a moving part of the machine and a
static object.
Shearing
Where one part of a machine moves together with another part of the machine and causes one
to move (on top of the other).
Cutting/severing
Whereby a part of the operator is cut or severed by a sharp edge or moving part of the
machine.
Entanglement
Where a rotating part of the machine gets caught with the operator's clothing (drawing the
operator into the machine).
Drawing in/trapping
Where the body or parts of the body, are drawn into the machine (caused by two moving
parts of the machine).
Impact
Where a person is hit by a powered part of the machine.
Stabbing/puncture/ejection
Where the person’s skin is penetrated by a part of the machine or process.
Friction/abrasion
Where the person comes into contact with a fast- moving part of the machine.
High pressure fluid injection

Where the pressure of fluid in a system penetrates the skin and tissues of the person.
The classification of non-mechanical hazards
Noise
Is a hazard to both the operator and the operatives and others working nearby.
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Vibration
Can cause adverse effects to the body – such as problems with blood flow, or muscular
problems.
Electricity
Electric shock is the most obvious hazard, but fire and explosion are also associated.
High / low temperature

Workers who are either too hot or too cold can become affected i.e. through lack of
concentration, heat stroke etc.
Radiation
Are health hazards that must be controlled.
Hazardous substances
Some machines use and give off (as a waste product) substance hazardous to health.
Hazards from typical machines
Sample list of hazards are as follows:
Drills
(a) seizure of hair by revolving shafts, spindles, chucks and drills;
(b) entanglement of gloves, loose sleeves, bandages and rings, usually at the tip of the drill;
(c) violent spinning of the workpiece in the absence of proper clamping arrangements.
Circular saws
 Damaged blades.
 Loose blades.
 Loose guards.
 Operator error.
Guillotines
1) Cutting.
2) Drawing in.
3) Electricity.
4) Noise:
(a) the impact of the clamps on the stock;
(b) impact of the blade;
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(c) stock vibrating after the cut;
(d) fall of scrap at the rear of the machine;
(e) engagement of the clutch;
(f) noise from the electric motor;
(g) exhausting pneumatic valves.
Abrasive wheels
 Handling.
 Storage.
 Rotation speed.
 Sparks.
 Atmosphere.
 Noise.
 Friction and abrasion.
 Ejection (of parts of the wheel).
Lathes
 contact with rotating cutters;

 ejection of the work piece and/or cutter;
 trapping and crushing caused by moving carriages, swinging arms and moving turrets;
 unexpected movement or start-up caused by faults in the automatic cycling of the
machine;
 noise emission (often in excess of 100 dB(A));
 exposure to dust and chippings, often in excess of the maximum exposure limit
(MEL) of 5 mg/m3 (milligrammes per cubic metre) for hardwood and softwood dust.
Simple robots
 Drilling.
 Cutting.
 High pressure fluid.
 Impact.
 Contact.
Mechanical and hydraulic presses

 High pressure fluid.
 Crushing.
 Impact.
Portable power tools

Depending upon the tool:
 Vibration.
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 Sparks.
 Noise.
The factors to be considered when assessing risk
The risk assessment process should be adhered to:
Persons at risk
The operator.
Employees near by.
Visitors.
For each group, you must also decide on their numbers.
Severity of possible injury
If there is likely to be an injury, what type of injury is it likely to be?
Probability of injury
What is the probability of the machine causing an injury?
Need for access

Maintenance?
Repairs?
Duration of exposure
In relation to noise.
In relation to vibration.
(a) fixed enclosing guards;
The main types of safeguards
Within this section, we will examine the various methods of protection, exploring their
principles, merits and limitations:
 Fixed guards.
 Interlocked guards.
 Trip devices (light curtains, foot mats and sensitive edges).
 Adjustable/self-adjusting guards.
 Two-hand controls.
 Protective appliances.
 Personal protective equipment.
 Information, instruction, training and supervision.
Guards or protection devices must be used to protect risks such as moving parts.
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These must be of robust construction and not be easy to bypass. Fixed guards must be held in
place by fixings which can only be undone with tools. Movable guards should be interlocked.
Adjustable guards should be readily adjustable without the use of tools.
Electrical and other energy supply hazards must be prevented. There must be no risk of injury
from temperature, explosion, noise, vibration, dust, gasses or radiation. There must be proper
provision for maintenance and servicing. Sufficient indication and warning devices must be
provided. Machinery shall be provided with instructions for safe installation, use, adjustment
etc.
There are special requirements for agri-foodstuffs, hand-held, wood working machines and
also lifting and underground equipment.
Fixed guards
Fixed guards will prevent access to danger zones of machinery (which will contain moving
parts). Fixed guards have no moving parts and are fastened in a constant position, relative to
the danger zone:
They are kept in place permanently, by welding for example, or by means of fasteners.
Interlocked guards
Interlocked guards.
These are movable guards with interlocking switches.
If access is required, there needs to be a movable (openable) guard which is interlocked with
the power source of the hazard in a manner which ensures that whenever the guard door is
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not closed, the hazard power will be switched off. This approach involves the use of an
interlocking switch fitted to the guard door.
The control of the power source of the hazard is routed through the switch section of the unit.
The power source is usually electrical but it could also be pneumatic or hydraulic. When
guard door movement (opening) is detected, the interlocking switch will isolate the hazard
power supply either directly or via a power contactor (or valve).
Some interlocking switches also incorporate a locking device which locks the guard door
closed and will not release it until the machine is in a safe condition. For many applications,
the combination of a movable guard and an interlock switch with or without guard locking is
a reliable and cost-effective solution.
This type of guard will have benefits that:
 The hazardous machine functions covered by the guard cannot operate until the guard
is closed.
 If the guard is opened while hazardous machine functions are operating, a stop
instruction is given.
 When the guard is closed, the hazardous machine functions covered by the guard van
operate, but the closure of the guard does not itself initiate their operation.
Automatic guards
 Moved into position automatically by the machine

 Physically removes from the danger area any part of a person exposed to danger
Trip devices
Trip devices.
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These include:
 Light curtains.
 Foot mats.
 Sensitive edges.
When frequent access is required, physical guarding at the hazard is sometimes too restrictive
for part loading or adjustment. In this situation, a device is required which prevents
dangerous motion while allowing unrestricted access by sensing the presence of the operator
and sending a stop signal.
Photo-electric light curtains.
These devices emit a curtain of harmless infra-red light beams in front of the hazard area.
When any of the beams are blocked, the light curtain control circuit sends a stop signal to the
guarded machine. There are many factors which affect the type and positioning of a light
curtain.
Light curtains are extremely versatile and can guard areas many metres wide. By the use of
mirrors, the light beams can be diverted round corners to enclose a machine. They are
available with different light beam spacings making them suitable for many applications,
ranging from totally enclosing perimeter guards for industrial robots, to point of access
guards for certain types of presses.
Pressure-sensitive safety mats.
These devices are used to guard a floor area around a machine. A matrix of interconnected
mats is laid around the hazard area and any pressure (e.g. an operator's footstep) will cause
the mat controller unit to send a stop signal to the guarded machine.
Pressure-sensitive mats are often used within an enclosed area containing several machines
e.g. flexible manufacturing or robotics cells. When access may be required into the cell (for
setting or robot teaching, for example), they prevent dangerous motion if the operator strays
from the safe area.
Pressure-sensitive edges.
These devices are flexible edging strips which can be fixed to the edge of a moving part such
as a machine table or powered door, where there is a risk of a crushing or shearing hazard.
If the moving part strikes the operator (or vice versa) the flexible sensitive edge is depressed
and will send a stop signal to the power source. Sensitive edges can also be used to guard
machinery where there is a risk of operator entanglement. If an operator becomes caught up
and dragged by the machine, he will be pulled onto the sensitive edge thereby tripping its
switching action.
These trip devices do not actually restrict access but only sense it. They rely entirely on their
ability to both sense and switch. For the provision of safety therefore, it is important that their
control circuit be control-reliable. Also they must only be used in correct applications.
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In general, they are only suitable on machinery which stops immediately after removal of
power. Because an operator can walk or reach directly into the hazard area, it is necessary
that the time taken for the motion to stop is less than that required for the operator to reach
the hazard after tripping the device.
The following shows a photo-electric device fitted to a press brake:
Adjustable / Self-Adjusting Guards
Adjustable guards are guarding systems which require manual adjustment to give protection.
They are used on woodworking machinery, milling machines, lathes, drills and grinding
wheels.
Many of the guards are designed so the work-piece can be observed during machine
operation. Windows of polycarbonate or armoured plate glass allow the operator a clear view.
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Some systems are made with telescopic fencing or a slotted movable casting. Both systems
allow observation of the work-piece.
This kind of guarding can be difficult for the operator to use and is easy to defeat. However,
it is sometimes the only practicable method.
Adjustable guards and other guards which do not completely enclose the dangerous parts
should only be used in situations where it is not practicable to use fixed enclosing guards or
protection devices which would give a greater level of protection.
Two-hand controls
There are other ways of preventing access while the machine is in a dangerous condition. The
use of two hand controls (also referred to as bi-manual controls) is common on certain types
of machinery. Two start buttons have to be operated at the same time to run the machine.
This ensures that both hands of the operator are occupied in a safe position (i.e. at the
controls) and, therefore, cannot be in the hazard area.
Note: This type of measure only protects the operator and does not give protection to other
personnel.
A two-hand control system depends heavily on the integrity of its control and monitoring
system to detect any faults, so it is important that this aspect is designed to the correct
specification. The physical design should prevent improper operation (e.g. by hand and
elbow). The machine should not go from one cycle to another without the releasing and
pressing of both buttons. This prevents the possibility of both buttons being blocked, leaving
the machine running continuously. Releasing of either button must cause the machine to stop.
The use of two-hand control should be considered with caution as it usually leaves some form
of risk exposed.
It is very useful, however, on applications such as teach mode pendants and inching controls
because it can give enhanced levels of protection when used in conjunction with other
protective devices.
The figure below is of a cross-cut saw operated by two hand control and fitted with a short
tunnel guard.
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Mechanical restraints
A mechanical restraint is classed as ‘a device that applies mechanical restraint to a dangerous

part of machinery which has been set in motion owing to failure of the machinery controls or
other parts of the machinery, so as to prevent danger’ – BS EN 292.
Jigs and push sticks
Jigs and push sticks are used to hold a work piece in place when used on the machine.
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Safety information and appropriate training
All users of work equipment must be provided with adequate health and safety information.
The employer must make it available and may have to provide written instructions on the use
of work equipment. This means the workforce should have easy access to such information
and be able to understand it.
PPE
Personal protection (such as protective clothing and respirators) may be needed as an interim
measure where engineering controls are being developed and/or modified, and for short-term
jobs such as cleaning and maintenance. Engineering controls protect everyone in the
workplace; personal protective equipment can only help the person who wears it.
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Dust respirators filter the air breathed by the wearer in order to make it safe to breathe, and
are not suitable for use in situations where the amount of oxygen in the air may be deficient,
eg in confined spaces. These situations require breathing apparatus which provides air from
an independent source (eg a cylinder).
There are some simple masks, known as nuisance dust masks, which do not give any reliable
protection against substances hazardous to health.
Personal and work-related factors in selection of RPE.
All types of RPE restrict the wearer to some extent, by imposing extra breathing resistance on
the lungs and by restricting visibility or mobility. These restrictions underline the need to
control exposures by other means wherever possible. It is also important to remember that
effective protection is only given when equipment which is of the right standard, and in good
condition, is properly fitted and used. Removal of the RPE, even for short periods,
dramatically reduces thelevel of protection afforded to the wearer.
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Face masks depend on good contact between the skin and the mask for their effectiveness.
Many face masks are available in one size only and cannot be expected to fit all the working
population. A good fit and seal are essential - without them, the respirator will not give
effective protection. It is advisable to obtain a selection of different models of RPE so that
masks can be selected to give the best fit for individual wearers. It will only be possible to get
a good seal if the skin in the region of the seal is smooth and without hair. Facial hair or
glasses will tend to lift the mask off the face and permit inward leakage of contaminated air.
A simple check on how well a face mask fits can be done in the following way:
1 Put on the equipment according to the manufacturer’s instructions.
2 For disposable respirators, cup the hands over the whole of the face piece; for respirators
with separate filters, cover the inlet to the filter with the hands or with a flat sheet of card or
similar material.
3 Inhale sharply so that the mask collapses slightly. Hold the breath.
4 If the mask remains collapsed for a few seconds and no leakage is detected, the mask
probably fits adequately.
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5 If leakage is detected, the head straps should be readjusted and the test repeated. If leakage
persists, a different size or design of respirator is needed.
Training
Everyone who is involved in the use of RPE should be appropriately trained. They must be
aware of why the RPE is being worn and how it should be worn properly. Training may be
available from the supplier or manufacturer of your RPE.
Care of RPE.
The manufacturer’s recommendations should be followed on replacement of filters. Non-

disposable RPE should be cleaned and disinfected after each use, or at least once in every
working day. Rubber face pieces can usually be cleaned with soap and lukewarm water, but
the manufacturer’s instructions should always be followed.
Disposable respirators should be discarded after each shift, or more frequently if exposure is
high.
The Need for “Face-Fit” Tests.
Leaks are likely to occur in the system at points where joints are made, including:
• Outer edge of the face-piece, especially around the nose on half-mask respirators.
• Through the filter media.
• Around the filter media mounting.
• Through the exhalation valves.
• Hose couplings.
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Many types of RPE rely heavily on a good seal between the face and the face piece.
Face-Fit Test.
Applicable only to those pieces of RPE which rely heavily on a tight seal between face and
face piece for performance, e.g. filtering face piece, half-mask, full-face mask, etc.
Control Strategies for Biological Agents
We have already referred to the role of the Control of Substances Hazardous to Health
Regulations 2002 (COSHH) in the assessment and control of biological agents. The COSHH
Regulations set out a strategy of assessment and control for biological agents that require:
 An assessment of the risks to workers of exposure to biological agents.

 Exposure to be prevented by substitution of less hazardous agents.
 Introduction and testing of control measures.
 Informing employees of hazards encountered at work.
 Records kept of employees exposed to biological agents in Hazard Groups 3 and 4.
 Notification to the HSE of first use of biological agents in Hazard Groups 2, 3 and 4.
 Notification to the HSE of consignment or import of biological agents in Hazard
Group 4 and some in Group 3.
 Monitoring of employee exposure.
 Introduction of health surveillance where relevant.
The objectives of control measures are to prevent or minimise the escape of biological agents
and the risk of illness caused by exposure to biological agents if they do escape. The
philosophy of control is based on a series of “barriers” which serve to isolate the agent from
the person at risk.
Consequently the agent may be confined by:
Primary barriers around the hazard to prevent escape of the agent into the environment,
which include:
Physical containment.
Good laboratory practice.
Specially-designed equipment.
Secondary barriers to protect the worker by providing:
awareness of the hazard;
medical supervision;
personal protective equipment;
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washing and hygiene facilities.
Tertiary barriers around the premises to prevent:
access by unauthorised persons;
escape of solid, liquid and gaseous effluents and wastes.
The control measures employed for work with biological agents can be categorised and
prioritised in accordance with the hierarchy of control measures that we have encountered
previously. We shall look at these in turn.
The hierarchy of control:
Eradication,
Reduced virulence,
Change of work method to minimise or suppress generation of aerosols,
Isolation and segregation,
Containment,
Ventilation (HEPA filters),
Sharps control,
Immunisation,
Decontamination and disinfection.
Eradication
The first priority for control is always to eliminate or substitute the hazard for an agent that
presents a lower risk. In laboratory work, it may be possible to substitute virulent strains of
microbiological organisms with less virulent strains that will still give satisfactory laboratory
results. A number of laboratory practical experiments that previously would have used
biological materials have now been replaced with models or simulations.
The risk of Legionella contamination has been eliminated in a number of building air-
conditioning systems by taking spray humidification equipment out of use.
Reduced Virulence
It may be possible to substitute the hazard for an agent that presents a lower risk. In
laboratory work, it may be possible to substitute virulent strains of microbiological organisms
with less virulent strains that will still give satisfactory laboratory results.
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The risk of working with biological material in laboratories can be reduced by measures such
as screening human specimens for blood-borne virus infections and using heat treatment to
reduce the number of potentially hazardous organisms present.
Change of Work Method and Aerosols.
If micro-organisms are grown, then the culture medium is usually closed by a cotton wool
bung or a micro-filter. This will prevent the medium becoming contaminated from external
micro organisms and reduce the risk of the culture forming an aerosol. Aerosols can be
minimised by handling any liquid suspension in such a container.
In research laboratories, the containers have to be opened to remove samples, etc. therefore it
is important to minimise agitation. If an aerosol is likely to be produced, then it is important
to contain the aerosol in a suitable fume cupboard.
Isolation and Segregation
A common risk control method is to reduce individual exposure. In this context, work with
hazardous biological agents needs to be segregated from less hazardous work so only those
whose work requires them to come into close contact could ever be exposed. Similarly,
infected animals and, in hospitals, infected people may need to be isolated from others to
reduce the risk of any infection spreading.
Containment
The range of engineering controls available for biological agents is similar to that we
examined for chemical agents. You will remember that the controls included glove boxes
which provided complete containment and enclosure, fume hoods providing partial
containment and enclosure, local exhaust ventilation using captor hoods or receptor hoods to
capture the airborne contaminant at source, and dilution ventilation for low concentrations of
low toxicity contaminants.
However, because of the complexity of the way in which biological agents cause harm,
protection using engineering controls involves more than simply ensuring that workplace
exposure limits are not exceeded, which is the approach taken with chemical agents.
Engineering control for laboratory work with biological agents (health and veterinary care
facilities, laboratories and animal rooms) is based on the concept of "containment" and the
COSHH Regulations specify minimum levels of containment that correspond to the four
Hazard Groups that we examined earlier.
So, ordinarily a Hazard Group 2 Agent must be contained at Containment Level 2 as a

minimum, unless a higher hazard group agent is suspected of being present, in which case a
higher level is selected.
Level 1 is suitable for handling agents that are unlikely to cause human disease. In practice,
this means that no engineering controls are necessary, work takes place on the open bench but
aerosol production must be minimised and basic standards of good microbiological practice
observed.
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Level 2 involves the same measures, but procedures that are likely to give rise to infectious
aerosols must be carried out in microbiological safety cabinet.
Level 3 laboratories must be separated from other activities in the building, be sealable for
fumigation, be maintained at negative pressure and have extracted air filtered through a high
efficiency filter. Work would normally be carried out in a microbiological safety cabinet.
Level 4 laboratories are maximum containment facilities with entry through an airlock, input
and extract air filtered and work carried out in closed safety cabinets.
Filtration
Ideally, the air from any extraction unit should be filtered and discharged to the outside of the
building. In many cases, however, this is not practical. More often, filtration will be
considered as an alternative to external discharge.
Where soldering operations are carried out, an external wall or window filtration will be the
only options.
Where filters are used, they must be of a suitable type and regularly checked to ensure that
they are not saturated. Fumes from rosin-cored solder contain both particulates and gaseous
products, such as formaldehyde.
The filters must, therefore, be designed to deal with both — the particulate filter being
positioned before the gas filter to prevent it from being clogged. In some systems, it may be
possible to clean or replace the particulate filter several times before replacing the gas filter.
Effective filtration of particulates can be achieved by use of a High Efficiency Particle

Arrestor (HEPA) filter. Gaseous products a normally removed by an activated carbon filter.
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Ergonomics
What is ergonomics?
Ergonomics is a science concerned with the fit between people and their work. It puts people
first, taking both their limitations and capabilities into account. Ergonomics sets out to ensure
that tasks, equipment, information and the environment suit each worker.
To assess the fit between a person and their work, ergonomists have to consider many
aspects, including:
 the job being done

 the demands on the worker
 the equipment used (its size, shape, and how appropriate it is for the task)
 the information used (how it is presented, accessed, and changed);
the physical environment (temperature, humidity, lighting, noise, vibration);
 the social environment (such as teamwork and supportive management).
Ergonomists consider all the physical aspects of a person, such as:
 body size and shape

 fitness and strength
 posture
 the senses, especially vision, hearing and touch
 the stresses and strains on muscles, joints, nerves
Ergonomists also consider a person’s psychological aspects, such as:
 mental abilities
 personality
 knowledge
 experience
Out come of bad ergonomic systems may be
 Accidents
 Ill-health
Ergonomists make sure that equipment, facilities and systems are designed and organised to
the highest standards of health, comfort, efficiency and safety for those who use them. The
Ergonomics Society defines the discipline as 'the application of scientific information
concerning humans to the design of objects, systems and environment for human use.'
Ergonomists can use the findings of studies into the relationships between people,
environments and equipment to improve the way that people interact with processes and
systems. Areas of work include product/equipment design, production systems, information
and advanced technology and transport design.
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They may work in consultancy, research, development or teaching and may also be called
human factors specialists.
Typical work activities
An ergonomist’s work activities vary widely but are always based on ensuring that a system
or product meets the needs of the user and will usually include:
 investigating the physical capabilities and limitations of the human body;

 analysing how people use equipment and machinery;
 undertaking workplace risk assessments;
 assessing work environments and their effect on users;
 utilising assessment results to identify areas for improvement;
 designing practical solutions to implement these improvements;
 producing user manuals to ensure the best use of new systems or products;
 producing reports of findings and recommendations;
 writing proposals and compiling statistical data;
 using detailed knowledge of the human body to improve the design of products, such
as cars and leisure facilities;
 interviewing individuals and observing them in a particular type of environment, as
part of the research process;
 liaising with staff at all levels of an organisation to undertake research;
 visiting a range of environments, such as offices and factories, to assess health and
safety standards or to investigate workplace accidents;
 providing advice, information and training to colleagues and clients;
 acting as an expert witness in cases of industrial injury;
 developing a clear understanding of how specific industries and their systems work in
a short space of time;
 managing sections of projects;
 presenting to clients, conferences and professional societies;
 identifying opportunities for new work.
Health Surveillance
Definition
Health Surveillance can be defined as a process involving a range of strategies and methods
used to systematically detect and assess the early signs of adverse effects on the health of
workers exposed to certain health hazards; and subsequently acting on the results.
Some forms of health surveillance are required by law. Other forms of health surveillance are
undertaken as good practice, such as pre-employment assessments.
Management of Health Risks
Health Surveillance should be part of an overall strategy for management of health risks, and
not a substitute for preventing or controlling harmful exposure.
It is important that a suitably qualified individual chooses the right technique of surveillance
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to cause minimum harm to the individual, and in order not to cause unnecessary concern for
employees.
Purposes of Health Surveillance
 Protection of health of the individual employee.

 Detection at an early stage any adverse health effects.
 Assisting in the evaluation of control measures.
 Data may be used for detection of hazards and assessment of risk.
 Other purposes: e.g. immune status assessment.
Criteria for conducting Health Surveillance
 Is the activity or substance known to harm health? i.e. is it associated with an

identifiable disease or other identifiable adverse health outcome?
 Is there a valid technique for detecting indications of the disease or health effects?
Health surveillance is only worthwhile where it can reliably show that damage to
health is starting to happen or likely to happen. A valid technique is specific to the
disease to be identified, and is safe and practicable in the work setting.
 Is there a reasonable likelihood that the disease or health effect may occur under the
existing circumstances?
 Is it likely to benefit the employee?
Other Factors to consider
 Is there a statutory requirement to undertake health surveillance?

 Have there been previous cases of work related ill-health associated with the
activity/substance?
 Has an employee declared ill-health symptoms they attribute to their work?
 Do you use PPE e.g. gloves, respirators? They cannot be guaranteed to give 100%
protection.
 Must be done in consultation with employee as it may have implications for future
employment.

Types of Health Surveillance
1. Low level = Health Monitoring

Self-reporting of specific symptoms, enquiries, questionnaires
2. High Level = Medical Surveillance

Medical examination, blood tests, urine tests, lung function tests.
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Reducing Manual Handling Injury Risk
The Load - Reducing the risk of INJURY
Making it lighter
Where a risk of injury from manual handling of a load is identified, consider reducing its
weight. For example, liquids and powders can be packaged in smaller containers. Where
loads are bought in, it may be possible to specify lower package weights. However, the
breaking down of loads will not always be the safest course: do not overlook the consequent
increase of frequency of handling.
Making it smaller or easier to manage
Consider making loads less bulky so that they can be grasped more easily and the centre of
gravity brought closer to the handler's body. Again, it may be possible to specify smaller or
more manageable loads, or to redesign those produced in-house.
Making it easier to grasp
Where the size, surface texture or nature of a load makes it difficult to grasp, consider
providing handles, hand grips, indents or any other feature designed to improve the handler's
grasp. Alternatively, it may be possible to place the load securely in a container which is
easier to grasp. Where a load is bulky rather than heavy, it may be easier to carry it at the side
of the body if it has suitable handholds, or if slings or other carrying devices can be provided.
Making it more stable

Where possible, packaging should be such that objects will not shift unexpectedly while
being handled. Where the load, as a whole, lacks rigidity it may be preferable to use slings or
other aids to maintain effective control during handling.
Making it less damaging to hold

As far as possible, loads should be clean and free from dust, oil, corrosive deposits etc. To
prevent injury during the manual handling of hot or cold materials, an adequately insulated
container should be used; failing this, suitable handling aids or PPE will be necessary. Sharp
corners, jagged edge, rough surfaces etc should be avoided where possible.
Kinetic handling techniques
Good Handling Technique
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There is no single way to lift, and many different approaches are put forward. The following
list illustrates the important points as suggested by the Manual Handling Operations
Regulations 1992:
Stop and Think:
Plan the lift.
 Where is the load going to be placed? Use appropriate handling aids if possible.
 Do you need help with the lift?
 Remove obstructions such as discarded wrapping materials.
Place the feet
 Have the feet apart, giving a balanced and stable base for lifting (tight skirts and
unsuitable footwear make this difficult).
 Have the leading leg as far forward as is comfortable.
Adopting a good posture
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 Bend the knees so that the hands when grasping the load are as level with the waist as
possible.
 Do not kneel or over-flex the knees. Keep the back straight, maintaining its natural
curve.
 Lean forward a little over the load if necessary to get a good grip.
 Keep shoulders level and facing in the same direction as the hips.
Get a firm grip
 Try to keep the arms within the boundary formed by the legs.
 The optimum position and nature of the grip depends on the circumstances and
individual preference, but it must be secure.
 A hook grip is less fatiguing than keeping the fingers straight.
 If it is necessary to vary the grip as the lift proceeds, do this as smoothly as possible.
 Don't jerk: carry out the lifting movement smoothly, raising the chin as the lift begins
and keep control of the load.
Keep close to the load
 Keep the load close to the trunk for as long as possible.
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 Keep the heaviest side of the load next to the trunk. If a close approach to the load is
not possible, try sliding the load towards you before attempting to lift it.
Put down, then adjust
If precise positioning of the load is necessary, put it down first, then slide it into the desired
position.
MSDS
Material safety data sheet is a chemical or product specific health and safety reference. It is
prepared by the manufacturer of each hazardous chemical and contains much of health and
safety information necessary to perform a protocol risk assessment. You should refer an
MSDS whenever you begin working with a new chemical and periodically to see if the
information has changed. Although the format for MSDS vary widely, the information found
within them is consistent and includes:
 Physical and chemical properties

 Health hazard information include short and long term exposure effects.
 Permissible exposure limits and symptoms of overexposure.
 A description of how to safely handle the substance under normal and emergency
situations.
 A description of what first aid and medical treatment is appropriate if excessively
exposed.
The Purpose of the MSDS
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The MSDS is the second element of the WHMIS information delivery system, and
supplements the alertinformation provided on labels. The third element of the system is
the education and training of workers inhazard information on controlled products,
including instruction in the content and significance of informationon the MSDS.
The MSDS is an essential starting point in the development of a worksite program for the
safe use of
controlled products. It serves as:
• A technical information reference
• A starting point for the implementation of control measures to protect workers
• A document that can be distributed to persons in work areas where the product is used
and to those withresponsibilities related to MSDS content, for example, health and safety
coordinators and committees, firstaid personnel, and fire response teams
• A key element of worker education and training
• A simple means for updating a program when revisions to MSDSs become available
An MSDS cannot represent all the information needed for the safe use of a product.
Product use and thepotential for worker exposure vary from one work location to another.
The variety of required protectivemeasures cannot be anticipated through one data sheet.
Therefore, the development of jobsite instructionalmaterials and written work procedures,
based on the MSDS, may be necessary to provide plainly writtendirection to workers.
An MSDS is not a document that is meant to be read once and filed. The MSDS must be
incorporated into anactive program of worker protection.
MSDS DETAILS
1. Action Level - The exposure level (concentration in air) at which OSHA regulations
to protect employees takes effect (29 CFR 1910.1001-1047); e.g. workplace
airanalysis, employee training, medical monitoring, and recordkeeping. Exposure at
or above action level is termed occupational exposure. Exposure below this level can
also be harmful. This level is generally half the PEL.
2. Acute Exposure. Exposure of short duration, usually to relatively high

concentrations or amounts of material.
3. Air Purifying Respirator - A respirator that uses chemical sorbents to remove

specific gases and vapors from the air or that uses a mechanical filter to remove
particulate matter. An air purifying respirator must only be used when there is
sufficient oxygen to sustain life.
4. Allergen -A substance that causes an allergic reaction.
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5. Allergy -A condition in which an initial symptomless exposure to a specific allergen

later gives rise to a sensitivity to further exposure. Symptoms may be exhibited in a
variety of ways, usually by respiratory distress or skin eruptions.
6. Asphyxiant-A vapor or gas that can cause unconsciousness or death by suffocation

(lack of oxygen). Most simple asphyxiants are harmful to the body only when they
become so concentrated that they reduce (displace) the available oxygen in the air
(normally about 21%) to dangerous levels (18% or lower). Examples of simple
asphyxiants are carbon dioxide, nitrogen, hydrogen, and helium. Chemical
asphyxiants like carbon monoxide (CO) reduce the blood's ability to carry oxygen, or
like cyanide, interfere with the body's utilization of oxygen.
7. AutoignitionTemperature - The minimum temperature at which a substance ignites

without application of a flame or spark. Do not heat materials to greater than 80% of
this temp.
8. Boiling Point, BP -The temperature at which a liquid's vapor pressure equals the
surrounding atmospheric pressure so that the liquid rapidly vaporizes. Flammable
materials with low BPs generally present special fire hazards [e.g. butane, BP = -
0.5ºC (31ºF); gasoline, BP = 38ºC (100ºF)). For mixtures, a range of temperature is
given.
9. Carcinogen. A material that either causes cancer in humans, or, because it causes
cancer in animals, is considered capable of causing cancer in humans.
10. Ceiling Limit, C. The concentration not to exceed at any time. "An
employee's exposure [to a hazardous material] shall at no time exceed the ceiling value"
(OSHA).
11. CEIL -Certification Engineers International Ltd.
12. Chronic Exposure. Continuous or intermittent exposure extending over a long time
period, usually applies to relatively low material amounts or concentrations.
13. Chronic Health Effect. An adverse effect on a human or animal body with
symptoms that develop slowly over a long time period and persist or that recur
frequently.
14. Chronic Toxicity. A material's property that produces chronic health effects (see
above), usually resulting from repeated doses of or exposure to the material over a
relatively prolonged time period. Ordinarily used to denote effects noted in
experimental animals.
15. Combustible. A term the NFPA, DOT, and others use to classify certain materials
with low flash points that ignite easily. Both NFP A and DOT generally define
combustible liquids as having a flash point of 38ºC (100ºF) but below 93.3ºC
(200ºF).
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16. Corrosive. A chemical that causes visible destruction of or irreversible alterations in

living tissue by chemical action at the site of contact, or that causes a severe
corrosion rate in steel or aluminum.
17. Cryogenic. Relating to extremely low temperatures as for refrigerant gases
18. Engineering Controls. Engineering control systems reduce potential hazards by

isolating the
worker from the hazard or by removing the hazard from the work environment. Methods
include substitution, ventilation, isolation, and enclosure. This is preferred over
administrative controls and personal protective equipment.
19. Explosive. A material that produces a sudden, almost instantaneous release of

pressure, gas, and heat when subjected to abrupt shock, pressure, or high
temperature.
20. Exposure Limits. The concentration in workplace air of a chemical deemed the
maximum acceptable. This means that most workers can be exposed at given levels
or lower without harmful effects. Exposure limits in common use are:
a. TLV-TWA (threshold limit value-time weighted average); b. STEL (short-term
exposure limit)
c. C (ceiling value).
21. Flammable. Describes any solid, liquid, vapor, or gas that ignites easily and burns
rapidly. Both NFPA and DOT generally define flammable liquids as having a flash
point below 38ºC (100ºF)
22. Flammable Limits (Flammability Limits, Explosive Limits). Minimum and

maximum concentrations of a flammable gas or vapor between which ignition can
occur. Concentrations below the lower flammable limit (LFL) are too lean to burn,
while concentrations above the upper flammable limit (UFL) are too rich. All
concentrations between LFL and UFL are in the flammable range, and special
precautions are needed to prevent ignition or explosion.
23. Flash Point(FP) - Lowest temperature at which a flammable liquid gives off
sufficient vapor to form an ignitable mixture with air near its surface or within a
vessel. Combustion does not continue. FP is determined by laboratory tests in cups.
24. Fume-An airborne dispersion of minute solid particles arising from the heating of a
solid (such as molten metal, welding).
25. Gas. A formless fluid that occupies the space of its enclosure. It can settle to the
bottom or top of an enclosure when mixed with other materials. It can be changed to
its liquid or solid state only by increased pressure and/or decreased temperature.
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26. General Ventilation (Also known as dilution ventilation). The removal of

contaminated air and its replacement with clean air from the general workplace area
as opposed to local ventilation, which is specific air changing in the immediate area
of a contamination source. An example of local ventilation is a laboratory fume hood.
27. Hazard Communication. Requires chemical manufacturers and importers to assess

the hazards associated with the materials in their workplace (29 CFR 1910.1200).
Material safety data sheets, labeling, and training are all results of this law.
28. Hazardous Chemical, Material. In a broad sense, any substance or mixture of

substances having properties capable of producing adverse effects on the health or
safety of a human. Included are substances that are carcinogens, toxic, irritants,
corrosives, sensitizers, and agents that damage the lungs, skin, eyes, mucous
membranes, etc.
29. HEPA - High-efficiency particulate air filter. Has a 99.97% removal efficiency for
.03-micron particles.
30. Incompatible. Describes materials that could cause dangerous reactions and the
release of energy from direct contact with one another.
31. Irritant - A chemical, which is not corrosive, but which causes a reversible
inflammatory effect on living tissue by chemical action at the site of contact.
32. Label. Any written, printed, or graphic sign or symbol displayed on or affixed to
containers of hazardous chemicals. A label should identify the hazardous material,
appropriate hazard warnings, and name and address of the chemical manufacturer,
importer, or other responsible party.
33. Latency Period. Time that elapses between exposure and first manifestations of
disease or illness. Latency periods can range from minutes to decades, depending on
hazardous material and disease produced.
34. Local Ventilation. The drawing off of contaminated air directly from its source. This
type of ventilation is recommended for hazardous airborne materials. Treatment of
exhausted air to remove contaminants may be required.
35. Lower Explosive Limit, Lower Flammable Limit. Refers to the lowest
concentration of gas or vapor (% by volume in air) that bums or explodes if an
ignition source is present at ambient temperatures.
36. Material Safety Data Sheet. Also MSDS. Material safety data sheet. OSHA has
established guidelines for descriptive data that should be concisely provided on a data
sheet to serve as the basis for written hazard communication programs. The thrust of
the law is to have those who make, distribute, and use hazardous materials
responsible for effective communication.
37. Mutagen - A substance or agent capable of altering the genetic material in a living
cell.
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38. Neurotoxin - A material that affects the nerve cells and may produce emotional or
behavioural abnormalities.
39. NFPA. National Fire Protection Association.
40. NIOSH. National Institute of Occupational Safety and Health.
41. Nonflammable -Incapable of easy ignition. Does not bum, or bums very slowly.
Also, a DOT hazard class for any compressed gas other than a flammable one.
42. Nuisance Particulates. Dusts that do not produce significant organic disease or toxic
effect from "reasonable" concentrations and exposures.
43. Odor Threshold. The lowest concentration of a material's vapor (or a gas) in air that
is detectable by odor.
44. OSHA. The Occupational Safety and Health Administration. Part of the U.S.
Department of Labor.
45. Oxidizer. The DOT defines an oxidizer or oxidizing material as a substance that
yields oxygen readily to stimulate the combustion (oxidation) of organic matter.
Chlorate (CIOI23), permanganate (Mn04), and nitrate (NO) compounds are examples
of oxidizers. Note that they all contain large amounts of oxygen (0).
46. PEL. Permissible Exposure Limit. Established by OSHA. This may be expressed as
a time weighted average (TWA) limit, short-term exposure limit (STEL), or as a
ceiling exposure limit. A ceiling limit must never be exceeded instantaneously even
if the TWA exposure limit is not violated. OSHA PELs have the force of law. Note
that ACGIH TLVs and NIOSH RELs are recommended exposure limits.
47. Physical Hazard. Means a chemical for which there is scientifically valid evidence
that it is a combustible liquid, a compressed gas, explosive, flammable, and organic
peroxide, an oxidizer, pyrophoric, unstable (reactive) or water-reactive.
48. Polymerization - A chemical reaction in which one or more small molecules

combine to form larger molecules. A hazardous polymerization is such a reaction that
takes place at a rate that releases large amounts of energy.
49. PPE. Personal protective equipment. Devices or clothing worn to help insulate a
worker from direct exposure to hazardous materials. Example include gloves and
respirators.
.
50. Reactivity. A substance's tendency to undergo chemical reaction either by itself or
with other material with the release of energy. Undesirable effects such as pressure
buildup, temperature increase, or formation of noxious, toxic, or corrosive by-
products may occur because of the substance's reactivity to heating, burning, direct
contact with other materials, or other conditions in use or in storage.
51. Reproductive Health Hazard/Toxin. Any agent with a harmful effect on the adult
male or female reproductive systems or on the developing fetus or child. Such
hazards affect people in many ways, including loss of sexual drive, mental disorders,
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impotence, infertility, sterility, mutagenic effects on germ cells, teratogenic effects

on the fetus, and transplacental carcinogenesis.
52. Respirator. A variety of devices that limit inhalation of toxic materials. They range
fromdisposable dust masks to self-contained breathing apparatus (SCBA). All have
specific usesand limitations. Their use is covered by OSHA, 29 CFR 1910.134 See
SCBA, ChemicalCartridge Respirator.
53. Routes of Entry. To do bodily damage, a material must contact the body. The
method of bodily contact is called the route of entry. The routes of entry are: I)
absorption (eye or skin contact); 2) ingestion; and 3) inhalation.4) injection
54. Synonyms. Alternative names by which a material may be known.
55. Spontaneously Combustible - A material that ignites as a result of retained heat

from processing, or which will oxidize to generate heat and ignite, or which absorbs
moisture to generate heat and ignite.
56. Target Organ Effects. Chemically-caused effects from exposure to a material on

specific listed organs and systems such as liver, kidneys, nervous system, lungs, skin
and eyes.
57. Teratogen - A substance or agent, exposure to which by a pregnant female can result
in Malformations in the fetus.
58. TLV. Threshold limit value. A term used to express the airborne concentration of a
material to which most workers can be exposed during a normal daily and weekly
schedule without adverse effects. ACGIH expresses TLV s in three ways: 1) TLV
TWA, the allowable time weighted average concentration for a normal 8-hour
workday or 40-hour week; 2) TLV STEL, the short-term exposure limit or maximum
concentration for a continuous exposure period of 15 minutes (with a maximum of
four such periods per day, with at least 60 minutes between exposure periods, and
provided that the daily TLV- TWA is not exceeded); and 3) Ceiling (C), the
concentration not to exceed at any time.
59. Toxicology. The study of the nature, effects, and detection of poisons in living
organisms. Also, substances that are otherwise harmless but prove toxic under
particular conditions. The basic assumption of toxicology is that there is a
relationship among the dose (amount), the concentration at the affected site, and the
resulting effects.
60. Toxic Substance. Any chemical or material that: 1) has evidence of an acute or
chronic health hazard and 2) is listed in the NIOSH Registry of Toxic Effects of
Chemical Substances (RTECS), provided that the substance causes harm at any dose
level; causes cancer or reproductive effects in animals at any dose level; has a median
lethal dose (LD50) of less than 500 mg/kg of body weight when administered orally
to rats; has a median LD50 of less than 1000 mg/kg of body weight when
administered by continuous contact to the bare skin of albino rabbits; or has a median
lethal concentration (LD50) in air of less than 2000 ppm by volume of gas vapor, or
less than 20 mg/L of mist, fume, or dust when administered to albino rats.
193
61. Upper Explosive Limit, Upper Flammable Limit. VEL, UFL. The highest
concentration ofa material in air that produces an explosion or fire, or that ignites
when it contacts an ignition source (high heat, electric arc, spark, or flame). Any
concentration above the UEL in air is too rich to be ignited. See Flammable Limits.
62. Vapor. The gaseous state of a material normally encountered as liquid.
63. Vapor density - The weight of a vapor or gas compared to the weight of an equal
volume of air is an expression of the density of the vapor or gas.
64. VOC. Volatile organic compounds. Used in coatings and paint because they
evaporate very
rapidly. Regulated by the EPA per the Clean Air Act.
65. CAS No. : The unique identification number assigned each compound registered
with the Chemical Abstracts Service (CAS). The number allows one to uniquely
identify a chemical regardless of the naming system.
66. U.N. No. : United Nations (UN) Numbers are four-digit numbers used world-wide in
international commerce and transportation to identify hazardous chemicals or classes
of hazardous materials. These numbers generally range between 0000 and 3500 and
are ideally preceded by the letters "UN" (for example, "UN1008") to avoid
confusion with other number codes.
67. Shipping Name : Name indicted against the specific U.N. No.
Codes/Label/Class : The classification of goods by the type of goods invloved. The hazards
transport of goods is sub-divided to show the primary hazard of the substance, which
determines the Class into which the substance is assigned, and, where appropriate, the
subsidiary risks.
The classifications identified are those adopted by the United Nations Committee of Experts
on the Transport of Dangerous Goods and on the Globally Harmonised System of
Classification and Labelling of Chemicals, and are as follows:
a. Class 1: Explosives: Substances which may explode under the effect of flame heat, heat or
photo chemical conditions, or which are more sensitive to shocks or friction than
dinitrobenzene. A substance which is not itself an explosive but which can form an explosive
atmosphere of gas, vapour or dust is not generally included in Class 1.
b. Class 2: Gases –compressed, liquefied, dissolved under pressure or deeply refrigerated.

Some gases are flammable; others non-flammable.
194
c. Class 3: Inflammable (flammable) liquids: These are liquids or mixture of liquids, or

liquids containing solids in solution or suspension having flash point of not more than 60.5
degree C (closed-cup), or not more than 65.6 degree C (open-cup).
d. Class 4:
i. Inflammable solids
ii. Substances liable to spontaneous combustion
iii. Substances which, in contact with water, emit flammable gases.
e. Class 5:
i. Oxidising substances
ii. Organic peroxides
f.Class 6:
i. Poisonous (toxic) substances

ii. Infectious substances
g. Class 7:Radioactive substances
h. Class 8:Corrosive substances
i. Class 9: Miscellaneous dangerous substances not covered by other classes.
68. HazchemCode :Emergency Action codes (EACs), also known as Hazchem, are for
the use of the emergency services in conjunction with Emergency Action Code
Cards. EACs indicate to the emergency services actions that may be necessary,
during the first few minutes of an incident involving dangerous goods, should the
officer in charge of the incident deem it necessary to take immediate actions. The
code uses one of the numerals 1, 2, 3 or 4 followed by one or two letters.
69. LD50 (Oral) :Lethal Dose Fifty (Oral) – a calculated orally ingested dose of a
material which is expected to cause the death of 50% of an entire defined
experimental animal population. Generally animals are rat, mouse or rabbit.
70. LC50 : Lethal Concentration Fifty – a calculated concentration of a material in air,

exposure to which for a specified length of time, hours (H), month (M), or week (W),
is expected to cause the death of 50% of entire defined experimental animal
population.
71. Permissible Exposure Limit : Permissible Levels of certain Chemical Substances in

Work Environment as laid down in the Second Schedule of the Factories Act.
72. Threshold Limit Value- Short-Term Exposure Limits: The parts of vapour (gas per
million parts of contaminated air by volume at 25 degree (77degreeF) and one
atmosphere pressure is given. The limits are given in milligrams per cubic 50 meter
maximum permissible average exposures for the time periods specified.
195
73. ppm : Parts per million parts of air.
74. mg/m3 : Milligram per cubic metre.
75. NFPA Hazard Signals : National Fire Protection Associations USA

Hazard Signal – A simple, readily recognizable and easily understood markings (alerting
signals) which give at a glance a general idea of the inherent hazards of the material and the
order of severity of these hazards as they relate to fire prevention, exposure and control. The
system identifies the hazards of a material in terms of three categories –
Health, Flammability and Reactivity, and indicates the order of severity in each of these
categories. Another category (special) is reserved for additional information when such may
be of value to the fire fighter.
76. ACGIH : The American Conference of Governmental Industrial Hygienists, Inc.,

ACGIH, is an organization open to all practitioners in industrial hygiene,
occupational health, environmental health, or safety.
77. Asphyxiant:-An asphyxiant is a substance that can cause unconsciousness or death

by suffocation (asphyxiation). Asphyxiants which have no other health effects and
are sometimes referred to as simple asphyxiants. Asphyxiants work by displacing so
much oxygen from the ambient atmosphere that the hemoglobin in the blood can not
pick up enough oxygen from the lungs to fully oxygenate the tissues. As a result, the
victim slowly suffocates.
78. Acute Exposure. Exposure of short duration, usually to relatively high

concentrations or amounts of material.
79. Chronic Exposure. Continuous or intermittent exposure extending over a long

timeperiod, usually applies to relatively low material amounts or concentrations.
80. Chronic Health Effect. An adverse effect on a human or animal body with
symptoms that develop slowly over a long time period and persist or that recur
frequently. See Acute Health Effect.
81. Chronic Toxicity. A material's property that produces chronic health effects (see
above), usually resulting from repeated doses of or exposure to the material over a
relatively prolonged time period. Ordinarily used to denote effects noted in
experimental animals.
82. Air Purifying Respirator - A respirator that uses chemical sorbents to remove
specific gases and vapors from the air or that uses a mechanical filter to remove
particulate matter. An air purifying respirator must only be used when there is
sufficient oxygen to sustain life.
83. Allergen -A substance that causes an allergic reaction.
84. Allergy. A condition in which an initial symptomless exposure to a specific allergen

later gives rise to a sensitivity to further exposure. Symptoms may be exhibited in a
variety of ways, usually by respiratory distress or skin eruptions.
196
85. Autoignition Temperature:- The minimum temperature at which a substance

ignites without application of a flame or spark. Do not heat materials to greater than
80% of this temperature.
86. Boiling Point, BP. The temperature at which a liquid's vapor pressure equals the
surrounding atmospheric pressure so that the liquid rapidly vaporizes. Flammable
materials with low BPs generally present special fire hazards [e.g. butane, BP = -
0.5ºC (31ºF); gasoline, BP = 38ºC (100ºF)). For mixtures, a range of temperature is
given.
87. Carcinogen. A material that either causes cancer in humans, or, because it
causescancer in animals, is considered capable of causing cancer in humans.
88. Ceiling Limit, C. The concentration not to exceed at any time. "An employee's
exposure [to a hazardous material] shall at no time exceed the ceiling value"
(OSHA).
89. Combustible. A term the NFPA, DOT, and others use to classify certain materials
with low flash
points that ignite easily. Both NFP A and DOT generally define combustible liquids as
having a
flash point of 38ºC (100ºF) but below 93.3ºC (200ºF).
90. Engineering Controls. Engineering control systems reduce potential hazards by isolating
theworker from the hazard or by removing the hazard from the work environment. Methods
includesubstitution, ventilation, isolation, and enclosure. This is preferred over administrative
controlsand personal protective equipment.
91. Explosive:-A material that produces a sudden, almost instantaneous release of pressure,
gas, and heat when subjected to abrupt shock, pressure, or high temperature.
92. Exposure Limits:-The concentration in workplace air of a chemical deemed the

maximumacceptable. This means that most workers can be exposed at given levels or lower
withoutharmful effects. Exposure limits in common use are: 1) TLV-TWA (threshold limit
value-time weighted average); 2) STEL (short-term exposure limit); and 3) C (ceiling value).
93. Flammable:-Describes any solid, liquid, vapor, or gas that ignites easily and burns
rapidly. Both FPA and DOT generally define flammable liquids as having a flash point below
38ºC (100ºF)
94.Flammable Limits (Flammability Limits, Explosive Limits :- Minimum and

maximumconcentrations of a flammable gas or vapor between which ignition can occur.
Concentrationsbelow the lower flammable limit (LFL) are too lean to burn, while
concentrations above theupper flammable limit (UFL) are too rich. All concentrations
between LFL and UFL are in theflammable range, and special precautions are needed to
prevent ignition or explosion.
197
95.Flash Point(FP),Lowest temperature at which a flammable liquid gives off sufficient

vapor toform an ignitable mixture with air near its surface or within a vessel. Combustion
does notcontinue. FP is determined by laboratory tests in cups.
96.Fume.An airborne dispersion of minute solid particles arising from the heating of a solid
(such
as molten metal, welding).
97.Gas.A formless fluid that occupies the space of its enclosure. It can settle to the bottom or
topof an enclosure when mixed with other materials. It can be changed to its liquid or solid
stateonly by increased pressure and/or decreased temperature.
98.General Ventilation (Also known as dilution ventilation). The removal of contaminated

airand its replacement with clean air from the general workplace area as opposed to
localventilation, which is specific air changing in the immediate area of a contamination
source. An
example of local ventilation is a laboratory fume hood.
99.Hazard Communication :-Requires chemical manufacturers and importers to assess

thehazards associated with the materials in their workplace (29 CFR 1910.1200). Material
safetydata sheets, labeling, and training are all results of this law.
100. Hazardous Chemical, Material :-In a broad sense, any substance or mixture of
substanceshaving properties capable of producing adverse effects on the health or safety of a
human.Included are substances that are carcinogens, toxic, irritants, corrosives, sensitizers,
and agentsthat damage the lungs, skin, eyes, mucous membranes, etc.
101. HEPA :-High-efficiency particulate air filter. Has a 99.97% removal efficiency for 0.03-
micron
MATERIAL SAFETY DATA SHEET (MSDS) FORMAT
1. IDENTIFICATION OF THE SUBSTANCE / PREPARATION AND

COMPANY UNDERTAKING
Product Name:
Product Information:
Company Name:
Address:
Phone No.
198
Fax No.
2. COMPOSITION / INFORMATION ON INGREDIENTS
Chemical Name:
Product Code:
Hazardous Ingredients / Components:
CAS No.
Other Components: Risk Phrases & Symbol
For e.g.: Xi = Irritant, R36 = Irritating to eyes, R37 = Irritating to respiratory system,
R38 = Irritating to skin
3. HAZARDS IDENTIFICATION
Health: Inhalation
Skin Contact
Eye Contact
Ingestion
Fire:
4. FIRST – AID MEASURES

Inhalation:
Skin Contact:
Eye Contact:
Ingestion:
5. FIRE FIGHTING MEASURES

Extinguishing media:
Fire Fighting Protective Equipment:
Specific Hazards:
6. ACCIDENTAL RELEASE MEASURES

Personal precautions:
Environmental precautions:
199
Method for cleaning up:
7. HANDLING AND STORAGE

Handling:
Storage
8. EXPOSURE CONTROL / PERSONAL PROTECTION

Engineering measures:
Respirators
Eye Protection
Personal protective equipment:
Gloves
Safety glasses
Occupational Exposure Limits – Hazardous Ingredients
9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance:
Form:
Colour:
Odour:
PH (Value):
Boiling Point:
Melting Point:
Flash Point:
Flammable Limits:
Auto Ignition Temperature:
Explosive Properties:
Oxidising Properties:
Vapour Pressure (mm Hg):
Density (g/ml):
Solubility (Water):
200
Solubility (Other):
Partition Coefficient:
10. STABILITY AND REACTIVITY

Hazardous Reactions:
Hazardous Decomposition Product(s):
Conditions to avoid:
Materials to avoid:
11. TOXICOLOGY INFORMATION

Inhalation (LC50):
Skin Contact (Dermal – LD50):
Eye Contact:
Ingestion (Oral – LD50)
12. ECOLOGICAL INFORMATION

Environmental Hazards:
Persistence and Degradation:
Toxicity:
Effect on Effluent Treatment:
13. DISPOSAL CONSIDERATIONS

Product & contaminated packaging:
14. TRANSPORT INFORMATION

IATA:
ADR:
IMO:
UN NO.:
15. REGULATORY INFORMATION
Classification and labeling Danger symbol:
Danger Label:
Safety phrases:
16. OTHER INFORMATION
201
S-phrases are defined in Annex IV of European UnionDirective 67/548/EEC: Safety advice

concerning dangerous substances and preparations. The list was consolidated and
republished in Directive 2001/59/EC, where translations into other EU languages may be
found. The list was subsequently updated and republished in Directive 2006/102/EC, where
translations to additional European languages were added.
These safety phrases are used internationally and not just in Europe, and there is an ongoing
effort towards complete international harmonization. (Note: missing S-number combinations
indicate phrases that were deleted or replaced by another phrase.)
 S1: Keep locked up

 S2: Keep out of the reach of children
 S3: Keep in a cool place
 S4: Keep away from living quarters
 S5: Keep contents under ... (appropriate liquid to be specified by the manufacturer)
 S6: Keep under ... (inert gas to be specified by the manufacturer)
 S7: Keep container tightly closed
 S8: Keep container dry
 S9: Keep container in a well-ventilated place
 S10: Keep contents wet
 S11: not specified
 S12: Do not keep the container sealed
 S13: Keep away from food, drink and animal foodstuffs
 S14: Keep away from ... (incompatible materials to be indicated by the manufacturer)
 S15: Keep away from heat
 S16: Keep away from sources of ignition - No smoking
 S17: Keep away from combustible material
 S18: Handle and open container with care
 S20: When using do not eat or drink
 S21: When using do not smoke
 S22: Do not breathe dust
 S23: Do not breathe gas/fumes/vapour/spray (appropriate wording to be specified by the
manufacturer)
 S24: Avoid contact with skin
 S25: Avoid contact with eyes
 S26: In case of contact with eyes, rinse immediately with plenty of water and seek
medical advice
 S27: Take off immediately all contaminated clothing
 S28: After contact with skin, wash immediately with plenty of ... (to be specified by the
manufacturer)
 S29: Do not empty into drains
 S30: Never add water to this product
 S33: Take precautionary measures against static discharges
 S35: This material and its container must be disposed of in a safe way
 S36: Wear suitable protective clothing
 S37: Wear suitable gloves
 S38: In case of insufficient ventilation wear suitable respiratory equipment
 S39: Wear eye/face protection
202
 S40: To clean the floor and all objects contaminated by this material use ... (to be
specified by the manufacturer)
 S41: In case of fire and/or explosion do not breathe fumes
 S42: During fumigation/spraying wear suitable respiratory equipment (appropriate
wording to be specified by the manufacturer)
 S43: In case of fire use ... (indicate in the space the precise type of fire-fighting
equipment. If water increases the risk add - Never use water)
 S45: In case of accident or if you feel unwell seek medical advice immediately (show the
label where possible)
 S46: If swallowed, seek medical advice immediately and show this container or label
 S47: Keep at temperature not exceeding ... °C (to be specified by the manufacturer)
 S48: Keep wet with ... (appropriate material to be specified by the manufacturer)
 S49: Keep only in the original container
 S50: Do not mix with ... (to be specified by the manufacturer)
 S51: Use only in well-ventilated areas
 S52: Not recommended for interior use on large surface areas
 S53: Avoid exposure - obtain special instructions before use
 S56: Dispose of this material and its container at hazardous or special waste collection
point
 S57: Use appropriate containment to avoid environmental contamination
 S59: Refer to manufacturer/supplier for information on recovery/recycling
 S60: This material and its container must be disposed of as hazardous waste
 S61: Avoid release to the environment. Refer to special instructions/safety data sheet
 S62: If swallowed, do not induce vomiting: seek medical advice immediately and show
this container or label where possible
 S63: In case of accident by inhalation: remove casualty to fresh air and keep at rest
 S64: If swallowed, rinse mouth with water (only if the person is conscious)
Combinations
 (S1/2): Keep locked up and out of the reach of children

 S3/7: Keep container tightly closed in a cool place
 S3/7/9: Keep container tightly closed in a cool, well-ventilated place
 S3/9/14: Keep in a cool, well-ventilated place away from ... (incompatible materials to be
indicated by the manufacturer)
 S3/9/14/49: Keep only in the original container in a cool, well-ventilated place away from
... (incompatible materials to be indicated by the manufacturer)
 S3/9/49: Keep only in the original container in a cool, well-ventilated place
 S3/14 Keep in a cool place away from ... (incompatible materials to be indicated by the
manufacturer)
 S7/8: Keep container tightly closed and dry
 S7/9: Keep container tightly closed and in a well-ventilated place
 S7/47: Keep container tightly closed and at temperature not exceeding ... °C (to be
specified by the manufacturer)
 S8/10: Keep container wet, but keep the contents dry
 S20/21: When using do not eat, drink or smoke
 S24/25: Avoid contact with skin and eyes
 S27/28: After contact with skin, take off immediately all contaminated clothing, and
wash immediately with plenty of ... (to be specified by the manufacturer)
 S29/35: Do not empty into drains; dispose of this material and its container in a safe way
203
 S29/56: Do not empty into drains, dispose of this material and its container at hazardous
or special waste collection point
 S36/37: Wear suitable protective clothing and gloves
 S36/37/39: Wear suitable protective clothing, gloves and eye/face protection
 S36/39: Wear suitable protective clothing and eye/face protection
 S37/39: Wear suitable gloves and eye/face protection
 S47/49: Keep only in the original container at temperature not exceeding ... °C (to be
specified by the manufacturer
list of R-phrases
R-phrases (short for Risk Phrases) are defined in Annex III of European UnionDirective
67/548/EEC: Nature of special risks attributed to dangerous substances and preparations. The
list was consolidated and republished in Directive 2001/59/EC, where translations into other
EU languages may be found.
These risk phrases are used internationally, not just in Europe, and there is an ongoing effort
towards complete international harmonization. (Note: missing R-number combinations
indicate phrases that were deleted or replaced by another phrase.)
 Risk phrases
 R1:Explosive when dry

 R2: Risk of explosion by shock, friction, fire or other sources of ignition
 R3: Extreme risk of explosion by shock, friction, fire or other sources of ignition
 R4: Forms very sensitive explosive metallic compounds
 R5: Heating may cause an explosion
 R6: Explosive with or without contact with air
 R7: May cause fire
 R8: Contact with combustible material may cause fire
 R9: Explosive when mixed with combustible material
 R10: Flammable
 R11: Highly flammable
 R12: Extremely flammable
 R14: Reacts violently with water
 R15: Contact with water liberates extremely flammable gases
 R16: Explosive when mixed with oxidising substances
 R17: Spontaneously flammable in air
 R18: In use, may form flammable/explosive vapour-air mixture
 R19: May form explosive peroxides
 R20: Harmful by inhalation
 R21: Harmful in contact with skin
 R22: Harmful if swallowed
 R23: Toxic by inhalation
 R24: Toxic in contact with skin
 R25: Toxic if swallowed
 R26: Very toxic by inhalation
 R27: Very toxic in contact with skin
 R28: Very toxic if swallowed
204
 R29: Contact with water liberates toxic gas.

 R30: Can become highly flammable in use
 R31: Contact with acids liberates toxic gas
 R32: Contact with acids liberates very toxic gas
 R33: Danger of cumulative effects
 R34: Causes burns
 R35: Causes severe burns
 R36: Irritating to eyes
 R37: Irritating to respiratory system
 R38: Irritating to skin
 R39: Danger of very serious irreversible effects
 R40: Limited evidence of a carcinogenic effect
 R41: Risk of serious damage to eyes
 R42: May cause sensitisation by inhalation
 R43: May cause sensitisation by skin contact
 R44: Risk of explosion if heated under confinement
 R45: May cause cancer
 R46: May cause heritable genetic damage
 R48: Danger of serious damage to health by prolonged exposure
 R49: May cause cancer by inhalation
 R50: Very toxic to aquatic organisms
 R51: Toxic to aquatic organisms
 R52: Harmful to aquatic organisms
 R53: May cause long-term adverse effects in the aquatic environment
 R54: Toxic to flora
 R55: Toxic to fauna
 R56: Toxic to soil organisms
 R57: Toxic to bees
 R58: May cause long-term adverse effects in the environment
 R59: Dangerous for the ozone layer
 R60: May impair fertility
 R61: May cause harm to the unborn child
 R62: Possible risk of impaired fertility
 R63: Possible risk of harm to the unborn child
 R64: May cause harm to breast-fed babies
 R65: Harmful: may cause lung damage if swallowed
 R66: Repeated exposure may cause skin dryness or cracking
 R67: Vapours may cause drowsiness and dizziness
 R68: Possible risk of irreversible effects
Combinations
 R14/15: Reacts violently with water, liberating extremely flammable gases

 R15/29: Contact with water liberates toxic, extremely flammable gases
 R20/21: Harmful by inhalation and in contact with skin
 R20/22: Harmful by inhalation and if swallowed
 R20/21/22: Harmful by inhalation, in contact with skin and if swallowed
 R21/22: Harmful in contact with skin and if swallowed
 R23/24: Toxic by inhalation and in contact with skin
 R23/25: Toxic by inhalation and if swallowed
205
 R23/24/25: Toxic by inhalation, in contact with skin and if swallowed

 R24/25: Toxic in contact with skin and if swallowed
 R26/27: Very toxic by inhalation and in contact with skin
 R26/28: Very toxic by inhalation and if swallowed
 R26/27/28: Very toxic by inhalation, in contact with skin and if swallowed
 R27/28: Very toxic in contact with skin and if swallowed
 R36/37: Irritating to eyes and respiratory system
 R36/38: Irritating to eyes and skin
 R36/37/38: Irritating to eyes, respiratory system and skin
 R37/38: Irritating to respiratory system and skin
 R39/23: Toxic: danger of very serious irreversible effects through inhalation
 R39/24: Toxic: danger of very serious irreversible effects in contact with skin
 R39/25: Toxic: danger of very serious irreversible effects if swallowed
 R39/23/24: Toxic: danger of very serious irreversible effects through inhalation and in
contact with skin
 R39/23/25: Toxic: danger of very serious irreversible effects through inhalation and if
swallowed
 R39/24/25: Toxic: danger of very serious irreversible effects in contact with skin and if
swallowed
 R39/23/24/25: Toxic: danger of very serious irreversible effects through inhalation, in
contact with skin and if swallowed
 R39/26: Very Toxic: danger of very serious irreversible effects through inhalation
 R39/27: Very Toxic: danger of very serious irreversible effects in contact with skin
 R39/28: Very Toxic: danger of very serious irreversible effects if swallowed
 R39/26/27: Very Toxic: danger of very serious irreversible effects through inhalation and
in contact with skin
 R39/26/28: Very Toxic: danger of very serious irreversible effects through inhalation and
if swallowed
 R39/27/28: Very Toxic: danger of very serious irreversible effects in contact with skin
and if swallowed
 R39/26/27/28: Very Toxic: danger of very serious irreversible effects through inhalation,
in contact with skin and if swallowed
 R42/43: May cause sensitization by inhalation and skin contact
 R48/20: Harmful: danger of serious damage to health by prolonged exposure through
inhalation
 R48/21: Harmful: danger of serious damage to health by prolonged exposure in contact
with skin
 R48/22: Harmful: danger of serious damage to health by prolonged exposure if
swallowed
 R48/20/21: Harmful: danger of serious damage to health by prolonged exposure through
inhalation and in contact with skin
 R48/20/22: Harmful: danger of serious damage to health by prolonged exposure through
inhalation and if swallowed
 R48/21/22: Harmful: danger of serious damage to health by prolonged exposure in
contact with skin and if swallowed
 R48/20/21/22: Harmful: danger of serious damage to health by prolonged exposure
through inhalation, in contact with skin and if swallowed
 R48/23: Toxic: danger of serious damage to health by prolonged exposure through
inhalation
206
 R48/24: Toxic: danger of serious damage to health by prolonged exposure in contact with
skin
 R48/25: Toxic: danger of serious damage to health by prolonged exposure if swallowed
 R48/23/24: Toxic: danger of serious damage to health by prolonged exposure through
inhalation and in contact with skin
 R48/23/25: Toxic: danger of serious damage to health by prolonged exposure through
inhalation and if swallowed
 R48/24/25: Toxic: danger of serious damage to health by prolonged exposure in contact
with skin and if swallowed
 R48/23/24/25: Toxic: danger of serious damage to health by prolonged exposure through
inhalation, in contact with skin and if swallowed
 R50/53: Very toxic to aquatic organisms, may cause long-term adverse effects in the
aquatic environment
 R51/53: Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic
environment
 R52/53: Harmful to aquatic organisms, may cause long-term adverse effects in the
aquatic environment
 R68/20: Harmful: possible risk of irreversible effects through inhalation
 R68/21: Harmful: possible risk of irreversible effects in contact with skin
 R68/22: Harmful: possible risk of irreversible effects if swallowed
 R68/20/21: Harmful: possible risk of irreversible effects through inhalation and in contact
with skin
 R68/20/22: Harmful: possible risk of irreversible effects through inhalation and if
swallowed
 R68/21/22: Harmful: possible risk of irreversible effects in contact with skin and if
swallowed
 R68/20/21/22: Harmful: possible risk of irreversible effects through inhalation, in contact
with skin and if swallowed
R-phrases no longer in use
 R13: Extremely flammable liquefied gas.

 R47: May cause birth defects.
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Gas cylinder handling rules
Storage
 The gas cylinder storage shed must be located in an isolated area, as practicable.
 The gas cylinder storage shed shall have roofing to protect from direct sunlight and
have adequate ventilation.
 All gas cylinders shall not be stored in exits or egress routes.
 All gas cylinders shall not be stored in damp areas, near salt or corrosive chemicals,
fumes, heat or in areas exposure to the weather.
 The gas cylinder storage shed shall not be located close to any inflammable chemicals
/ fuel storage area / source of combustion activities / open flames / steam pipes.
 Full and empty cylinders are to be stored separately.
 The gas cylinders shall be stored in segregated manner, considering incompatibility
(example bulk DA & bulk Oxygen; bulk Hydrogen & bulk Oxygen, bulk LPG & bulk
Oxygen, toxic and flammable gas cylinders). Incompatible gas cylinders must be
stored at least at a gap of 3 meters.
 Incompatible gas cylinders must not be transported together.
 The store in-charge / supervisor shall maintain the up-to-date inventory of Gas
cylinders.
 All gas cylinders shall not be stored longer than one year without use.
 Other than notified gas cylinders, no other material of any kind shall be stored inside
the area.
 All the gas cylinders shall be kept in upright position with chaining to prevent
accidental fall.
 All gas cylinders shall be capped when not in use.
 All gas cylinders shall be stored so that cylinders are used in the order in which they
are received.
 The gas cylinder shall not have any loose electrical cables, wires or lines in the
vicinity.
 Do not keep cylinders in battery room or oil storage room.
 Adequate warning signs / labeling / no smoking caution / safety instructions shall be
displayed in the gas cylinder storage area in legible manner.
HANDLING AND USAGE
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 Gas Cylinders shall be handled only by properly trained persons. Training must
include the contents of this guideline as well as any specific information relevant to
the gas being used.
 Instructions shall be issued to all suppliers for mandatory affixing of cap guards,
providing color coding and warning sticker as per Gas Cylinder Rules, 1981. In
addition, supplier shall issue Test and Inspection Certificates.
 Do not issue a cylinder unless contents are not clearly identified.
 Do not alter the color coding and marking of Gas Cylinders, as given below.
Type of Gas Cylinder Color Coding

Non-flammable & non-toxic --
Non-flammable but toxic Yellow
Flammable but non-toxic other than LPG Red
Flammable and toxic Red and Yellow
 Do not use cylinders as rollers, work supports or jacks (sliding, dropping or playing
with cylinders shall be strictly prohibited.)
 Any unidentified gas cylinder found at the site or during excavation should not be
used. The presence of such a gas cylinder should be informed to the safety
department immediately. The gas cylinder should be handed over to the safety
department in no time.
 Prevent damage to cylinders. Locate cylinders where they will be protected from
physical damage by striking or falling objects, corrosion or damage from public
tampering.
 Containers shall not be used for any other purpose than holding the contents as
received.
 Damaged or leaking cylinders must be reported immediately for proper disposal.
Cylinders shall not be picked up by pulling the cap.
 Magnets shall not be used for lifting cylinders.
 Where appropriate lifting attachments have not been provided on the
cylinder/container, suitable cradles or platforms to hold the containers shall be used
for lifting.
 Do not use welded cylinders
 Leaking, defective, fire burned and corroded containers shall not be used.
 Do not use chain slings for lifting cylinders; only fiber sling should be used.
 Do not allow cylinders to come in contact with electrical apparatus or live wires.
 Do not lay gas cylinders on wet soil.
 Do not lubricate cylinders valve threads.
 Do not handle cylinders or valve assemblies with greasy hands or oil rags
 Oil or grease shall not come in contact with the cylinder valve assembly or the
regulator fittings.
 Use red hose for acetylene and other fuel gases and black / green hose for oxygen.
Never interchange hoses.
 To train workmen to handle and store dangerous cylinders properly and in case of
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any problem, it has to be capped and sent back to the supplier.

 Nozzle tips shall be always kept clean to prevent back fire.
 Use hoses of equal length and do not coil the hoses around regulator or cylinder.
 Close valves on gas cylinders when a system is not in use.
 Remove all pressure from regulators not currently used (by opening equipment
valves downstream after the regulators are closed).
 Shut-off valves must not be installed between pressure relief devices and the
equipment they are to protect.
 Use pressure relief valves in downstream lines to prevent high pressure buildup in
the event that a regulator valve does not seat properly and a tank valve is left on.
 Relief valves should be vented to prevent potential buildup of explosive or toxic
gases.
 Never allow flames or concentrated heat sources to come in contact with a gas
cylinder.
 Never allow a gas cylinder to become part of an electrical circuit.
 Never use cylinder gas as compressed air.
 Pressurize the regulators slowly and ensure that valve outlets and regulators are
pointed away from all personnel when cylinder valves are opened.
 Cylinders which require a wrench to open the main valve shall have the wrench left
in place on the cylinder valve while it is open. Use adequately sized wrenches (12”
long) to minimize ergonomic stress when turning tight cylinder valves. Never apply
excessive force when trying to open the valves. Cylinders with “stuck” valves
should be returned to suppliers to have valves repaired.
 Do not attempt to open a corroded valve; it may be impossible to reseal.
 Valves should only be opened to the point where gas can flow into the system at the
necessary pressure. This will allow for quicker shutoff in the event of a failure or
emergency.
 Use a cylinder cap hook to loosen tight cylinder caps. Never apply excessive force
or pry off caps. Return to supplier to remove “stuck” caps.
 Keep piping, regulators and other apparatus gas tight to prevent gas leakage.
 Confirm gas tightness by using compatible leak test solutions (e.g., soap and water)
or leak test instruments.
 Release pressure from systems before connections are tightened or loosened and
before any repairs.
 Never use adapters or exchange fittings between cylinder and regulators.
Manifolds, Valves and Regulators
The following information applies to the use of manifolds, valves and/or regulators
 Where compressed gas containers are connected to a manifold, the manifold and its
related equipment, such as regulators, shall be of proper design for the product(s)
they are to contain at the appropriate temperatures, pressures and flows.
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 Use only approved valves, regulators, manifolds, piping and other associated
equipment in any system that requires compressed gas. Care must be taken to
ensure that pressure gauges on regulators are correct for the pressure of the gas
cylinder used.
 Valves and regulators should undergo periodic maintenance and repair. A visual
inspection should be performed before each use to detect any damage, cracks,
corrosion or other defects. Long term maintenance or replacement periods vary with
the types of gases used, the length of use, and conditions of usage.
 Valves and regulator maintenance histories should be known before usage. Valves
that pass visual inspection are still subject to failure, therefore it is critical that toxic
or poisonous gases are used in ventilated enclosures and have local exhaust
ventilation in place for downstream pressure relief valves, etc.
 Valves and regulators should only be repaired by qualified individuals
 Display the license no. if the number of LPG cylinders stored is more than five.
GASES WITH SPECIFIC HAZARD CLASSES
The following information regarding specific classes of gases is offered as additional

guidance to be used in conjunction with the general usage requirements listed previously:
Flammable Gases
 Flammable gases, except for protected fuel gases, shall not be used near ignition
sources. Ignition sources include open flames and sparks, sources of heat, oxidizing
agents and ungrounded or non-intrinsically safe electrical or electronic equipment.
 Portable fire extinguishers shall be available for fire emergencies. The fire
extinguisher must be compatible with the apparatus and the materials in use.
 Flames shall not be used for detecting leaks. A compatible leak detection solution
shall be used for leak detection.
 Spark proof tools shall be used when working with or on a flammable compressed gas
cylinder or system.
 Access doors to areas which use or store flammable gases shall be have a display
prohibiting open flames
Fuel, High Pressure and Oxidizing Gases
 Oxidizing gases are non-flammable gases (e.g., oxygen), but in the presence of an
ignition source and fuel can support and vigorously accelerate combustion. Do not use
oil in any apparatus where oxygen will be used.
Toxic and Highly Toxic Gases
 Unless otherwise indicated, all gases must be stored in a continuously mechanically

ventilated gas cabinet, fume hood or other enclosure.
HANDLING LEAKS AND EMERGENCIES
Preplanning
211
Despite strict adherence to safety practices, accidents involving gases may occur. Users of
compressed gas cylinders must be familiar with necessary safety precautions. Standard
Operating Procedures for using compressed gases shall include a discussion of possible
accident scenarios, appropriate employee responses and should take into account the
following factors:
 The nature of the operation (e.g., equipment used and type of injury that might be
inflicted).
 The quantities of material that might be released and the type of containment (i.e.,
compressed gas tank size, manifold systems, etc.).
 The chemical and physical properties of the compressed gas
 The hazardous properties of the compressed gas (e.g., its toxicity, corrosivity and
flammability).
 The availability and locations of emergency supplies and equipment.
 A contingency plan which identifies building evacuation routes, emergency telephone
numbers, chemical containment procedures, fire extinguisher usage, etc., should be
posted at the site
Minor Leaks
Occasionally a gas cylinder or one of its component parts may develop a leak. Most of these
leaks occur at the top of the cylinder in areas such as the valve threads, pressure safety
device, valve stem and valve outlet. The following information applies to the remediation of
minor leaks:
 If possible, verify suspected leaks using a flammable gas detector or soapy water
solution (a flame should not be used for detection). If the leak cannot be stopped by
tightening a valve gland or packing nut, emergency action procedures should be
initiated and concerned person should be notified.
 For flammable, inert or oxidizing gases, the cylinder shall be moved to an isolated &
well-ventilated area away from combustible materials. Post signs that describe the
hazard.
 For corrosive and toxic gases, the cylinder shall be moved to an isolated, well-
ventilated area and use suitable means to direct the gas into an appropriate chemical
neutralizer if possible.
 If it is necessary to move a leaking cylinder through populated portions of the
building, place a plastic bag, rubber shroud or similar device over the top and tape it
(duct tape preferred) to the cylinder to confine the leaking gas.
Major Leaks
In the event of a large gas release or if an accident takes place in which readily available
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personal protective equipment (PPE) is inadequate to ensure worker safety, activate the
following Emergency Procedures:
 Immediately call Fire Brigade and report the incident.
 Activate building and area fire alarms.
 Evacuate the area, securing entrances and providing assistance to others on the way
out.
 Provide emergency response officials with details of the problem upon their arrival.
Accidents Involving Personnel Injury
Assist persons involved and administer immediate first aid which may include:
 Washing under a safety shower (in case of burning clothing or chemical exposures)
 Removing contaminated clothing.
 Wash the eyes properly at an eyewash.
 Administering artificial respiration.
 Notify personnel in adjacent areas of any potential hazards (e.g., activate building
or area alarms).
 Move injured personnel only if necessary to prevent their exposure to further harm.
Checklist of storage and handling of gas cylinders
Points Yes No NA
1. Storage area isolated, protected from sunlight, adequate
ventilation?
2. Is the storage area free from salt and corrosive chemicals fumes
and heat?
3. Are full and empty cylinders stored separately?
4. Are incompatible gas cylinders stored maintaining gap of 3

meters?
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5. Are cylinders kept upright and chained?
6. Are cylinder caps in position when not in use?
7. Are cap guards, collar coding and warning sticker as per Gas
Cylinder Rules, 1981?
8. Are cylinders free from oil or grease on valve threads?
9. Are hoses, red for acetylene, black/green for oxygen?
10. Are nozzle tips of gas cutters clean, in order to avoid back fire?
11. Is 12” long wrench available to open the main valve where
valve is sticky?
12. Are leak tests conducted?
13. Are fire extinguishers available?
14. Are more than 5 LPG cylinders stored? If yes, check license
number.
15. Is contingency plan available (building evacuation routes,

emergency telephone numbers, chemical containment procedures,
fire extinguisher usage)?
16. Is there any unclaimed gas cylinder at site? If yes, has safety
department been informed?
17. Is there any gas cylinder stored in contractor’s godown along

with other combustible material?
FIRE
One generally-accepted definition of combustion or fire is a process involving rapid oxidation

at elevated temperatures, accompanied by the evolution of heated gaseous products of
combustion, and the emission of visible and invisible radiation. Oxidation occurs all around
us in the form of rust on metal surfaces, and in our bodies by metabolising the food we eat.
However, the key word that sets combustion apart from other forms of oxidation is the word
"rapid".
The combustion process is usually associated with the oxidation of a fuel in the presence of
oxygen, with the emission of heat and light. Oxidation, in the strict chemical sense, means the
loss of electrons. For an oxidation reaction to occur, a reducing agent (the fuel) and an
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oxidising agent (usually oxygen) must be present. As heat is added, the ignition source, the
fuel molecules and oxygen molecules gain energy and become active. This molecular energy
is transferred to other fuel and oxygen molecules, which creates a chain reaction. A reaction
takes place where the fuel loses electrons and the oxygen gains electrons. This exothermic
electron transfer emits heat and/or light.
If the fire is in a fire grate or furnace, we refer to this process as a controlled fire and if it is a
building on fire, we refer to this process as an uncontrolled fire.
The combustion process occurs in two modes:
 The flaming.
 The non-flaming, smouldering or glowing embers.
For the flaming mode, it is necessary for solid and liquid fuels to be vaporised. The solid fuel
vapours are thermally driven off or distilled, and the liquid fuel vapours evaporated. It is this
volatile vapour from the solid or liquid fuels that we see actually burning in the flaming
mode. This gas or vapour production, emitted from the fuel is referred to as pyrolysis. Once a
flame has been established, heat transfer from the flame to the fuel surface continues to drive
off more volatile gases and perpetuates the combustion process.
Continued burning in the flaming mode requires a high burning rate, and the heat loss
associated with transfer of heat from the flame area by conduction, convection, and radiation
must be less than the energy output of the fire. If the heat loss is greater than the energy
output of the fire, the fire will extinguish.
There are three generally-recognised stages to a fire:
 the Induction stage,
 the Growth stage and
 the Decay stage.
Induction
The induction stage is the precursor to ignition where preheating, distillation and slow
pyrolysis are in progress. Gas minute particles are generated and transported away from the
source by diffusion, air movement and weak convection movement.
Growth (smoulder and flame)
The smouldering stage is a region of fully-developed pyrolysis that begins with ignition and
includes the initial stage of combustion. Invisible aerosol and visible smoke particles are
generated and transported away from the source by moderate convection patterns and
background air movement. The flaming stage is a region of rapid reaction that covers the
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period of initial occurrence of flame to a fully-developed fire. Heat transfer from the fire
occurs predominantly from radiation and convection from the flame.
Decay
In this (final) stage, the combustion is coming to and end, the fire is reducing in heat in a
constant manner, “the fire is burning itself out”. The decay stage does eventually occur
naturally; however, the fighting of a fire is about getting to this stage as quickly as possible.
Consider why this stage can occur naturally. It is also useful to be aware of the Steady State
Phase; this is the phase when, by various means or methods, the fire is coming under control.
The early stage of a fire, during which fuel and oxygen are virtually unlimited, is the Growth
Phase. This phase is characterised by an exponentially-increasing heat release rate.
The middle stage of a fire is the Steady State Phase. This phase is characterised by a heat
release rate which is relatively unchanging. Transition from the Growth Phase to the Steady
State Phase can occur when fuel or oxygen begins to be limited, or when suppression activity
begins to impact on the fire.
The final stage of a fire is the Decay Phase, which is characterised by a continuous
deceleration in the heat release rate, leading to fire extinguishment.
The fire triangle illustrates the rule that in order to ignite and burn, a fire requires three
elements - heat, fuel and oxygen. The fire is prevented or extinguished by removing any one
of them. Combustion occurs when the three elements are combined in the right mixture:
When a fire runs out of fuel, it will stop. This can happen as the process continues and the
fuel is consumed “the fire burns itself out”. The fuel can be physically removed, or by
chemically removing the fuel from the fire. Such techniques form the basis for most major
fire-fighting tactics. A good example of fuel separation is cutting fire breaks when fighting a
forest fire.
Without sufficient heat, a fire cannot begin, and it cannot continue. Heat can be removed by
dousing (some types of fire) with water; the water turns to steam, taking the heat with it.
Another example of removing heat from the fire triangle is separating burning fuels from
each other, and this can be an effective way to reduce the heat. Turning off the electricity in
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an electrical fire removes the heat source, (although other fuels may have caught fire and
continue burning.)
Oxygen may be removed from a fire by smothering it with aqueous foam, carbon dioxide, dry
chemicals, or enclosing it so that the fire will quickly use up all of the available oxygen. A
simple method of oxygen removal is the technique of blanketing; examples of blanketing
include covering a pan fire with a dampened cloth, or smothering a fire with a fire blanket.
The fire triangle remains an effective teaching tool, but does not demonstrate the fourth
element of fire, the sustaining chemical reaction.
This has led to development of the fire tetrahedron.
In the majority of circumstances the fire will fail to ignite, or is extinguished whichever
element is removed; however, there are certain chemical fires where knowledge of the fire
tetrahedron is essential.
The following diagram is a two-dimensional representation of the tetrahedron. It is useful to

visualise the fire tetrahedron as a pyramid having four sides including the bottom.
Combustion is the chemical chain reaction that feeds a fire more heat and allows it to
continue. With most types of fires, the old fire triangle model works well enough, but when
the fire involves burning metals, such as magnesium, lithium,sodium etc it becomes useful to
consider the chemistry of combustion.
Putting water on such a fire could increase the heat of the fire and could also be the catalyst
for an explosion. In this type of fire, specialised chemicals must be used to break the chain
reaction of metallic combustion, therefore extinguishing the fire.
Atomisation: The dispersion of a liquid into particles by a rapidly moving gas, liquid stream
or by mechanical means.
Combustion or burning is a chemical process, an exothermic reaction between a substance

(the fuel) and a gas (the oxidiser), usually O2, to release heat. In a complete combustion
217
reaction, a compound reacts with an oxidising element, and the products are compounds of
each element in the fuel with the oxidising element.
For example:
CH4 + 2 O2 → CO2 + 2 H2O + heat
CH2S + 6 F2 → CF4 + 2 HF + SF6 + heat
Rapid combustion
Rapid combustion is a form of combustion in which large amounts of heat and light energy
are released. This often occurs as a fire. This is used in forms of machinery, such as internal
combustion engines, and in thermobaric weapons.
Slower combustion
Slow combustion is a form of combustion which takes place at low temperatures. Respiration
is an example of slow combustion.
Complete combustion
In complete combustion, the reactant will burn in oxygen, producing a limited number of
products. When a hydrocarbon burns in oxygen, the reaction will only yield carbon dioxide
and water. When elements such as carbon, nitrogen, sulphur and iron are burned, they will
yield the most common oxides. Carbon will yield carbon dioxide. Nitrogen will yield
nitrogen dioxide. Sulphur will yield sulphur dioxide. Iron will yield iron (III) oxide.
Complete combustion is generally impossible to achieve unless the reaction occurs where
conditions are carefully controlled (e.g. in a lab environment).
Incomplete combustion
In incomplete combustion, there is an inadequate supply of oxygen for the combustion to

occur completely. The reactant will burn in oxygen, but will produce numerous products.
When a hydrocarbon burns in oxygen, the reaction will yield carbon dioxide, water, carbon
monoxide, and various other compounds such as nitrogen oxides. Incomplete combustion is
much more common and will produce large amounts of by-products and, in the case of
burning fuel in automobiles, these by-products can be quite lethal and damaging to the
environment.
Chemical equation
Generally, the chemical equation for burning a hydrocarbon (such as octane ) in oxygen is as
follows:
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CxHy + (x + y/4)O2 → xCO2 + (y/2)H2O

For example, the burning of propane is:
C3H8 + 5O2 → 3CO2 + 4H2O
The simple word equation for the combustion of a hydrocarbon is:
Fuel + Oxygen → Heat + Water + Carbon dioxide.
Combustion of liquid fuels
Combustion of a liquid fuel in an oxidising atmosphere actually happens in the gas phase, i.e.
it is the vapour that burns, not the liquid. Therefore, a liquid will normally catch fire only
above a certain temperature - its flash point. Below that temperature, the liquid will not
evaporate fast enough to sustain the fire.
Combustion of solid fuels
The act of combustion consists of three relatively distinct but overlapping phases:
 Preheating phase, when the unburned fuel is heated up to its flash point and then fire
point. Flammable gases start being evolved in a process similar to dry distillation.
 Distillation phase or gaseous phase, when the mix of evolved flammable gases with
oxygen is ignited. Energy is produced in the form of heat and light, flame is often
visible.
 Charcoal phase or solid phase, when the output of flammable gases from the material
is too low for persistent presence of flame and the charred fuel does not burn rapidly
anymore, but just glows and later only smoulders.
Combustion temperatures
Assuming perfect combustion conditions, such as an adiabatic (no heat loss) and complete
combustion, the adiabatic combustion temperature can be determined. The formula that
yields this temperature is based on the first law of thermodynamics and takes note of the fact
that the heat of combustion (calculated from the fuel's heating value ) is used entirely for
warming up fuel and gas (e.g. oxygen or air).
In the case of fossil fuels burnt in air, the combustion temperature depends on
 the heating value;

 the stoichiometric air ratio;
 the heat capacity of fuel and air;
 air and fuel inlet temperatures.
The adiabatic combustion temperature increases for higher heating values and inlet
temperatures and stoichiometric ratios towards one.
Identification of ignition sources

219
These sources of heat could include:
 smokers' materials, e.g. cigarettes and matches;
 naked flames;
 electrical, gas or oil-fired heaters (fixed or portable);
 hot processes (such as welding or grinding work);
 cooking;
 engines or boilers;
 machinery;
 faulty or misused electrical equipment;
 lighting equipment, e.g. halogen lamps;
 hot surfaces and obstruction of equipment ventilation, e.g. office equipment;
 friction, e.g. from loose bearings or drive belts;
 static electricity;
 metal impact (such as metal tools striking each other); and
 arson.
Most solid materials take up energy from any outer ignition source either by conduction,
convection or radiation (mostly by their combination), or are heated up as a result of the heat-
producing processes taking place internally that start decomposition on their surfaces.For
ignition to occur with liquids, these must have the formation of a vapour space above their
surface that is capable of burning. The vapours released and the gaseous decomposition
products mix with the air above the surface of liquid or solid material.
Ignition can be spontaneous, in that it does not necessarily require an open flame or spark if
the correct conditions are met.
A process of ignition is Pyrolysis - this is defined in the context of flame and fire as the stage
of ignition during which energy causes gas molecules given off by a heated fuel to vibrate
and break into pieces. Regardless of whether a fuel was originally a liquid or solid, the
overall burning process will gasify the fuel. It is the change of state of materials to become
gaseous, typically by evaporation; think of a burning wood fire where the wood itself may be
embers but 'gas flames' burn with it.
Confined Vapour Cloud Explosions (CVCE)
220
If a flammable vapour cloud is ignited inside a container (e.g. a process vessel, storage
container, or even a building), pressure can build up until the containing walls rupture.
CVCEs can cause considerable damage and could affect nearby plant where serious
secondary explosions could follow. (Abbeystead, 1984)
Unconfined Vapour Cloud Explosions (UCVCE)
If a flammable gas/air cloud burns in free space with sufficient rapidity to generate pressure
waves, which propagate through the vapour cloud and into the surrounding atmosphere, a
UCVE may result. (Nypro UK plant at Flixborough 1974)
Explosions
Explosions are sudden releases of energy, in this context resulting from a chemical reaction,
that lead to sudden and significant pressure rise. These can be classified as detonations if the
speed is greater than the speed of sound in the explosion medium, or, when the flame front
speed is less than the speed of sound, deflagrations. Detonations are much more destructive
than deflagrations. Dust explosions are unlikely to cause detonations due to the relatively
slow process of combusting solid particles.
Dust Explosions
A dust explosion is very similar to a gas or vapour cloud explosion, i.e. when a volume of a
flammable mixture is ignited, resulting in a rapid pressure increase and fire moving through
the cloud. A dust explosion occurs when a combustible material is dispersed in the air,
forming a flammable cloud and a flame propagates through it. This of course also depends on
the supply of oxygen to the fire, and the concentration of the fuel. If either of these are too
high or low, then the explosion will not occur.
Any solid material that can burn in air will do so at a rate that increases with increased
surface area. If the area available for combustion is high enough, then a flame can propagate
through the combustible mixture at high speeds. If the amount of heat released is sufficient to
cause further combustion, then the reaction will continue. If the heat release produces more
combustion than it took to generate, then the fire will not just continue, it will cause the fire
to grow very rapidly. If this is rapid enough, then the fire will become an explosion. The
maximum pressure in a dust explosion is typically around 5-12bar(g).
The explosion occurs in three stages, devolatisation (where volatiles are evaporated from the
particles, or the particle is vaporised), gas phase mixing and gas phase combustion.
Factors Affecting Ignition Sensitivity and Explosion Violence
Although particle size/specific surface area is the main factor in the estimation of the
likelihood of a dust explosion, there are other factors that will influence it:
 Chemical Composition of the dust (and its moisture content).
 Pressure and temperature of the gas.
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 Particle shape and size distribution.
 Degree of dispersion of the dust cloud.
 Concentration distribution in the dust cloud.
 Turbulence in the dust cloud.
 Amount of turbulence caused by the explosion in unburnt parts of the cloud.
 Flame front disturbance by mechanisms other than turbulence.
 Radiative heat transfer from the flame (dependent on chemistry).
Liquefied Propane Gas (LPG) Tank Hazards
LPG tank fires are structural fires, involving hazardous materials. Tackling them should only
be attempted by trained personnel using full structural personal protective equipment, and
equipped with a volume of water adequate to safely attack the fire.
Boiling Liquid Expanding Vapour Explosions (BLEVE)
A type of rapid phase transition in which a liquid contained above its atmospheric boiling
point is rapidly de dxpressurised, causing a nearly instantaneous transition from liquid to
vapour with a corresponding energy release. A BLEVE is often accompanied by a large
fireball if a flammable liquid is involved, since an external fire impinging on the vapour
space of a pressure vessel is a common BLEVE scenario. However, it is not necessary for the
liquid to be flammable to have a BLEVE occur.
A BLEVE or sudden complete failure of the tank is the most recognised hazard with LPG
tanks. BLEVEs are a major hazard to emergency responders.
Substance LEL UEL
Acetone 3% 13%
Acetylene 2.5% 100%
Benzene 1.2% 7.8%
Butane 1.8% 8.4%
Ethanol 3% 19%
Ethylbenzene 1.0% 1.7%
Ethylene 2.7% 36%
222
Diethyl ether 1.9% 36%
Diesel fuel 0.6% 7.5%
Gasoline 1.4% 7.6%
Hexane 1.1% 7.5%
Heptane 1.05% 6.7%
Hydrogen 4.1% 74.8%
Hydrogen sulphide 4.3% 46%
Kerosene 0.6% 4.9%
Methane 5.0% 15%
Octane 1% 7%
Pentane 1.5% 7.8%
Propane 2.1% 9.5%
Propylene 2.0% 11.1%
Styrene 1.1% 6.1%
Toluene 1.2% 7.1%
Xylene 1.0% 7.0%
Fire Fighting Equipment:
Unfortunately, there is no universal fire extinguishing agent. Therefore, there is a possibility

that some fire extinguishers, if used on ignited materials or liquids, may make the fire worse
and potentially put the employee (or person tackling the fire) at greater or increased
223
risk.Under the British Standard EN-2, fires have been divided into broad classifications for
extinguishing purposes. This will assist in selecting the most effective extinguishing agent to
be used on the most appropriate types of fire and burning material:
Class A
Fires involving solid materials where combustion normally takes place with the formation of
glowing embers
All solid materials, usually organic origin nature (contains compounds of carbon) and
generally produce glowing embers
Class B
fires involving liquids or liquefiable solids, fires involving cooking oils or fats
All flammable liquids and solids, which can also be sub-divided into:
Non-miscible with water (i.e. petrol, oils, solvents, paints & waxes)
Class C
fires involving gases and electricity
224
Fires involving Natural Mains Gas, Liquid Petroleum Gas (LPG - Butane & Propane etc),
Medical or Industrial gases.
Electrical Fires
Electrical fires are not considered to constitute a fire class on their own, as electricity is a
source of ignition that will feed the fire until removed. When the electrical supply has been
isolated, the fire can be treated (generally) as ‘Class A’ for extinguishing purposes. However,
you should always isolate the supply before fighting the fire; if this is not possible then a non-
electrical conducting extinguishing agent is to be used regardless of the power status on all
occasions.
Class D
fires involving metals
Fires involving metals (where water is generally ineffective and / or dangerous).

Specialist Dry Powders are produced for certain Class D fires, particularly those involving
alkali metals such as Sodium and Potassium. These Dry Powders extinguish metal fires by
fusing the powder to form a crust, which excludes oxygen from the surface of the molten
metal. A specific agent is added to prevent the powder from sinking into the surface of the
molten metals.
Types of fire portable extinguishers
The fire-fighting extinguishing medium in portable extinguishers is expelled by internal

pressure, either permanently stored or by means of a gas cartridge. Generally speaking,
portable fire extinguishers can be divided into five categories according to the extinguishing
medium they contain:
225
1.Water
2 Foam
3 Powder
4 Carbon Dioxide
5 Vaporising liquids
226
227
228
229
Common Cause of Industrial Fire :

• Leakages and spillages of flammable / combustible materials
• Electrical short circuiting / overloading
• Overheated bare surfaces / heaters / electric lamps
• Welding, cutting, soldering and other hot work
• Equipment Failure
• Smoking in prohibited areas
• Chemical reaction
• Friction heat / spark
• Spontaneous / combustion sparks / lightening
• Naked lights / connections
• Molten substances
• Arson etc.
230
Basic prevention method
• Ensure high housekeeping standards.

• Cover trash containers tightly and empty them regularly.
• Segregated flammable materials from sources of ignition.
• Promptly eliminate oil / gas leaks and clean spillage of flammable materials.
• Strictly adhere to work permit instruction for welding, cutting and other hot work in areas
where flammable substances are present.
• Store chemicals in separate.
• Where flammables substances are stored and used, ensure adequate ventilation, prohibi
smoking and use flameproof electrical equipment.
• Avoid multi-socket connection.
• Electrical repairs should be carried out by qualified personnel.
• Do not use damaged cords and avoid temporary connections.
• Lubricate, maintain and align all machines / equipments to prevent generation of heat.
Thank you and wishing you good luck
231

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EHS HAND BOOK- AHMED

INDEX PAGE NO, FROM TO

What is safety and why it is important?

Freedom from unacceptable risk or harm is called safety.

F - Follow Round the Year

One should remember the acronym ‘’ 5M’’

5. M - Mother Earth OR Environment

 Government regulation so suppliers know what standards their product is expected to

BS8800 defines a risk as “the combination of the likelihood and consequences of a

OHSAS 18001 defines a risk as a “combination of the likelihood and consequence(s) of a

Risk= likelihood of happening X consequence

Common Hazards and Descriptions

Chemical A chemical that, when exposed to a heat ignition source, results in

Explosion Sudden and violent release of a large amount of gas/energy due to

Electrical Contact with exposed conductors or a device that is incorrectly

Electrical Use of electrical power that result in electrical overheating or arcing to

Electrical Safety-critical equipment failure as a result of loss of power.

Excavation Soil collapse in a trench or excavation as a result of improper or inadequate

(Collapse) shoring. Soil type is critical in determining the hazard likelihood.

Mechanical Failure Self-explanatory; typically occurs when devices exceed designed

Mechanical Skin, muscle, or body part exposed to crushing, caught-between, cutting,

Safety is a multi-disciplinary subject and it includes following disciplines:

Three good reasons for preventing accidents in the workplace:

Ethical and Moral Considerations

There are two types of costs involved in any accident namely

Direct costs involve:-

 Lost time because of injured or deceased worker

Indirect costs involve:-

Role of the health and safety policy in decision making

Key elements of a good health and safety policy

• Overall aims of the organisation in terms of health and safety performance

An effective health and safety policy contains:

• A general statement of management commitment (What) - states the overall aims of

Resources for a good health and safety management system

The organisation should consider:

 The amount of support from senior management needed

Employer’s duties include:

Employee’s duties include:

The duty is often expressed as responsibilities to ensure that they:

Human factors which influence behaviour at work

Competence, skills, Task, work load,

The organisation needs to provide:

• Clear and evident commitment

Maslow’s hierarchy of needs

Perception:-“The way that a person views a situation”

Factors that influence the effectiveness are:

• A boring, repetitive job may result in a lowering of the impact of a stimulus

Errors and violations

There are two different types of human failure:

Errors and violations

Errors fall into three categories:

• Occur when something has gone wrong

The influence of peers

Individual factors: Job factors: Organisational factors:

 Increase skill and  Correct ergonomic  Good work planning

The “Four C’s”

General principles of communication:

Effects and benefits of training

• Better understanding and involvement raises staff morale/job satisfaction

• Reduces accident frequency and severity

Induction training for new workers

Key health and safety topics to be covered

• Review and discussion of the safety policy

• Regular refresher training