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Present Status and Improvement of Industrial Safety at Construction Sites Subhash M. Kodolkar and K. Ramprasad Industrial Plants Safety Division Atomic Energy Regulatory Board, Mumbai-400 094 E-mail: smkodolkar@ aerb.gov.in
Abstract This paper deals with the comparison of injury statistics of the construction sites and operating units of the power generating atomic energy installations. Injury statistics described in the tables & shown in few graphs reveals that the number of injuries, fatalities and man-days lost are comparatively higher at the construction sites as compared to operating units. Number of fatalities and man-days lost are around 8 times more at construction units than operating units, which poses a great challenge to industrial safety at construction sites. On an average, it is observed that every year one lost time injury takes place amongst 475 employees at construction units and amongst 875 employees at operating units. Comparing the number of minor injuries (lost time injuries/reported injuries) and major injuries (fatalities) occurred at operating units and at construction units, we can conclude that on an average 35 minor injuries have laid foundation of 1 major injury at operating units and 11 minor injuries have laid foundation of 1 major injury at construction units. It is evident that fall of persons & fall of objects from height are the major contributors for the injuries and high severity. Few safety precautions are highlighted in this paper in the form of suggestions to control the injuries and subsequent severity and to improve the industrial safety status at construction sites.
1. Introduction The progress of any country is measured in terms of development. Construction activities are the key to any development process, be it industrial, economic or social. As per Construction Industry Development Council (CIDC) Country Report 2005-06, annual turnover of the construction industry is around Rs. 3921 billion which is 6.2% to national GDP and providing employment to around 33 million workers, involving 4.7% engineers, 2.5% technicians & foreman, 15.3% skilled labours and 73.1% unskilled workers. From the above data it is clear that majority of the workers are unskilled and deployed at construction activities. As the duration of every construction activities at site is short and dynamic, the job of construction worker is temporary and migratory in nature. Construction work at a project site is carried out by number of contractors and their subcontractors. When construction work at site is in full swing, various activities are carried out simultaneously at different locations and at different elevations. Work of construction is carried out in more than one shift and even during late hours of night. When construction work is in progress the location of job and activities are dynamic and go on changing frequently posing unplanned hazards. The Construction Action Programme (CAP) of the International Labour Organisation (ILO) has specified that the poor record of the construction industry on occupational safety & health as one of the key problems and a cause
Present Status and Improvement of Industrial Safety at Construction Sites
47
of concern. This paper is being published taking into account this aspect and the increased number of loss time injuries & fatalities at construction activities as compared with operating units of the power generating atomic energy installations.
2. Applicable Legislations for Construction Activities Occupier has to comply with applicable legislation in his pursuit to minimise & control the injuries / damages, to the human being / equipment at construction works. Earlier, there were few legislations applicable for construction activities in India and those were skewed. In order to make comprehensive safety legislations, Government of India has enacted the following Act / Rules to safeguard construction workers (in addition to all other applicable Acts / Rules) : -
Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (BOCWA, 1996) which came in to effect from 1st March, 1996.
-
Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Rules, 1998 (BOCWR) which came in to effect from 11th November, 1998.
3. Present Scenario of Injury Statistics at Construction & Operating Units of Power Generating Atomic Energy Installations A comparative study of the injury statistics of some of the operating and the construction units of power generating atomic energy installations over the period of eight years has been carried out. The findings are as follows : Table : 1
2000 1999 1998 Total
Man Hours Worked
No. of Employees
No. of Man Days Lost
No. of Fatal Injuries
No. of Lost Time Injuries
Operating Units Man Hours Worked
No. of Employees
No. of Man Days Lost
No. of Fatal Injuries
Year 2005 2004 2003 2002 2001
No. of Lost Time Injuries
Construction Units
35 33 45 37 49
9 3 3 5 2
54975 20832 20219 34703 16569
26037 24383 21457 16648 10036
85506285 82834540 74919283 54457242 31440356
5 1 10 9 16
0 1 0 0 0
90 6000 252 149 274
12275 11857 13757 14228 11447
30053421 30785534 34611691 35937817 27947773
46 30 13 288
3 0 1 26
18909 579 6263 173049
11031 13640 13777 137009
26491384 32745560 21300000 409694650
15 16 33 105
0 0 2 3
237 1481 12642 21125
8747 9583 9599 91493
21846360 23856352 24231562 229270510
Proceedings of National Symposium on Industrial and Fire Safety 2006
Injury Trend Construction Units
Operating Units
60
Injuries
50 40 30 20 10 2005
2004
2003
2002
2001
2000
1999
1998
0
Year
Fig. 1.
Fatality Trend 10 8 6 4 2
Year Construction Units
Operating Units
Fig. 2.
2005
2004
2003
2002
2001
2000
1999
0 1998
Fatalities
48
Present Status and Improvement of Industrial Safety at Construction Sites
Trend in Man Days Lost
Man Days Lost
60000 50000 40000 30000 20000 10000 0 1998
1999
2000
2001
2002
2003
2004
2005
Year Construction Units
Operating Units
Fig. 3.
Trend in Employees 30000
Employees
25000 20000 15000 10000 5000 0 1998
1999
2000
2001
2002
2003
2004
Year Construction Units
Fig. 4.
Operating Units
2005
49
50
Proceedings of National Symposium on Industrial and Fire Safety 2006
Man Hours Worked
Trend in Man Hours Worked 90000000 80000000 70000000 60000000 50000000 40000000 30000000 20000000 10000000 0 1998
1999
2000
2001
2002
2003
2004
2005
Year Projects under construction
Operating Units
Fig. 5. It is found that the number of injuries, fatalities, man-days lost, number of employees and man hours worked are comparatively higher at the construction activities than operating units. Number of fatalities and man-days lost are at around 8 times more at construction sites than operating units in 8 years period. Hence, this possess a great challenge to industrial safety at construction sites Overall injuries, fatalities and man-days lost are in decreasing trend in this 8 year period in operating units. However, overall injuries, fatalities and man-days lost are in increasing trend at construction units. During the period of 8 years, 88.98% employees are increased at construction sites, whereas 27.87% employees are increased at operating units. This indicates that there is three fold increase in employees at construction units than operating units. As the number of employees are increased the Man Hours Worked (MHW) are also increased from about 2 crores to 8.5 crores at construction sites and from about 2.5 crores to 3 crores at operating units. At present, Man Hours Worked are 2.85 times more at projects under construction as compared to operating units. On an average every year one lost time injury takes place amongst 475 employees at construction activities and amongst 875 employees at Operating units.
Present Status and Improvement of Industrial Safety at Construction Sites
51
4. Concept on Foundation for Fatality (Major Injury) among Minor Injuries at Operating Units and Construction Units of Power Generating Atomic Energy Installations It was felt necessary to study and correlate the significance of the minor injury with respect to the occurrence of major injury. Exhaustive data with regard to first aid injuries and near miss incidents is not available. The compiled data on minor injuries (lost time or reported injuries) and major injuries (fatalities) that occurred at construction sites & operating units of power generating atomic energy installations for the last eight years period was available as indicated in Table No.1. Efforts were made to establish the relationship between Minor Injuries & Major Injuries. From the data it is seen that 3 fatalities occurred among 105 lost time injuries / reported injuries at operating units, which reveals that on an average 35 minor injuries (lost time or reported injuries) have laid down the foundation for 1 fatality (major injury) at operating units. However, at construction units, 26 fatalities occurred among 288 lost time injuries / reported injuries, which reveals that on an average 11 minor injuries (lost time or reported injuries) have laid down foundation for 1 fatality (major injury) at construction units. This relationship is described in following figures A, B and C.
Major Injuries
Major Injuries 26
3
288
105
(A)
(B)
Construction Units
Operating Units
Minor Injuries
Minor Injuries
Construction Units
Operating Units 11
Minor Injuries
1
35
Fatal
(C)
Fig. 7. Foundation for fatality
Minor Injuries
52
Proceedings of National Symposium on Industrial and Fire Safety 2006
Number of injuries at operating units are less as compared to construction activities because of following major aspects : -
Well established operating or manufacturing systems
-
Adequate, qualified and properly trained manpower
-
Involvement of management & their commitment at all levels (Top, Middle and Lower Management).
Number of injuries and subsequent fatalities at construction sites are more as compared to operating units because of following major reasons : -
Dynamic work situations & make-shift work practices
-
Inadequate, unskilled and improperly trained manpower
-
Because of inadequate and improper supervision there is less involvement & commitment of middle and lower management
-
Lack of proper coordination and communication between the departmental & contractors personnel.
-
Three fold increase in manpower at construction sites.
5. Comparison of Types of Accidents at Construction Sites of Power Generating Atomic Energy Installations Table 2
Type of Accidents at Construction Sites
1999 2000 2001
2002 2003 2004 2005 Total
Fall of Person
12
10
14
10
16
10
17
89
Fall of Object
1
15
14
14
11
9
9
73
Struck by Object
9
9
14
9
8
4
2
55
Caught in or between Object Over-exertion or wrong Movement Exposure to Extreme Temperature
2
6
4
4
5
4
2
27
0
1
1
0
0
0
0
2
3
2
1
0
2
3
0
11
Exposure to Electricity
2
2
0
0
3
1
5
13
Exposure to Harmful Substance
1
1
1
0
0
1
0
4
Explosion
0
0
0
0
0
1
0
1
30
46
49
37
45
33
35
275
Total
Present Status and Improvement of Industrial Safety at Construction Sites
53
Injuries
Type of Accidents 18 16 14 12 10 8 6 4 2 0 1999
2000
2001
2002
2003
2004
2005
Year Fall of Person
Fall of Object
Struck by Object
Caught in or between Object Fig. 8.
Study of injury statistics on construction sites for seven years from 1999 to 2005 shows that number of injuries and subsequent severity of these injuries resulted in fatalities because of majority of injuries are due to fall of persons and fall of objects from height. Out of 275 injuries 89 injuries (32%) are due to fall of persons and 73 injuries (26%) are due to fall of objects. This clearly indicates that much more concentration and attention is required towards working at height to control subsequent injuries & their severity. Other types of accidents leading to injuries are struck by objects (20%), caught in or between object (10%), exposure to electricity (5%) and exposure to extreme temperature (4%) etc.
6. Suggestions for Improvement in Safety Management & Engineering of Working Areas During regulatory inspections we had visited many construction sites and observed some generic and specific inadequacies in safety management & engineering practices at different working areas. Based on some major and frequently observed unsafe conditions and unsafe acts, following suggestions are highlighted to control the injuries and consequences like fatalities, man-days lost to improve the industrial safety status at construction sites.
6.1 6.1.1
Safety Organization & Management Commitments Construction site should have adequate and qualified Safety Officers & Safety Supervisors for their work.
54
Proceedings of National Symposium on Industrial and Fire Safety 2006
6.1.2
Workers participation in safety management should be encouraged by constitution of the Sectional Safety Committees for all Sections. The committees shall meet once in month to discuss and ensure health and safety of all employees and the neighborhood.
6.1.3
Specific works like working at height, work at confined spaces, electrical works etc. should be controlled by Safety Work Permit system.
6.1.4
Good engineering practices like Job Hazard Analysis should be carried out for specific & selected activities. Such practices should be followed at various work areas.
6.2
Industrial Hazard Control
6.2.1
As the maximum number of injuries at construction activities are due to fall of persons, fall of objects and struck by object, the personal protective equipment such as safety belt, helmet and safety shoes should be provided to all employees and their use should be strictly enforced by administrative measure.
6.2.2
All potentially dangerous & rotating parts such as flywheels of stone crushers and the rollers of the belt conveyors in the batching plant should be adequately guarded to prevent trapping of body parts / clothing of working personnel.
6.2.3
Floor opening should be either properly covered or provided with guard railing around it. Arrangement of rod bending facility and extreme end points of floor opening at higher elevation from where there is possibility of fall of persons should be provided with adequate guard railing. Considering the fall height provisions such as safety belt, nylon net, working platform with proper width should be enforced at the working at height.
6.2.4
Proper access should be provided for scaffolds and ladders used at various working areas. All scaffolds before use shall be examined by the Engineer-In-Charge of construction activities. Ladders should be qualified with the statutory requirements and should be inspected regularly and repaired immediately. No ladder with defective or missing rungs shall be used.
6.2.5
During the excavation proper shoring and bracing should be done to prevent sliding of excavated material over the persons working in the deep trench. Excavated trenches should be properly barricaded.
6.3
Fire Hazard Control
6.3.1
An approved fire fighting & protection system should be decided upon and installed as the construction activities go on progressing.
6.3.2
Hot work should be controlled and carried out only with proper safety precautions.
6.3.3
Welding cable shall be in good condition. It shall not lie on wet surface nor shall it pass through water or across the passage.
6.3.4
All gas cylinders should be provided with protective cap to their valves and proper chaining arrangement. Pressure gauges of the cylinders should be in healthy condition.
Present Status and Improvement of Industrial Safety at Construction Sites
55
6.3.5
Sufficient number of fire extinguishers shall be placed at strategic points. The testing of fire extinguishers should be done periodically to ensure that the extinguishers are in usable condition.
6.4
Industrial Hygiene & Occupational Health
6.4.1
High noise areas should be identified and noise level measurement should be carried out periodically for such areas. Proper engineering measures, if possible, should be implemented to bring down the noise at appropriate & acceptable levels. Use of suitable PPE such as earplugs and earmuffs should strictly be enforced in these areas to minimise the impact of high noise level.
6.4.2
The measurement of illumination level should be carried out periodically at various working areas and adequately improved. Person should not be allowed to work at a place having total darkness.
6.4.3
Adequate ventilation shall be provided at confined spaces & various work areas where there are chances of fumes/dusts being gathered. However, work at confined spaces should be carried out under the Safety Work Permit system.
6.4.4
First aid centre should be adequately manned & functional during the working hours at the construction sites. It should be equipped with an oxygen cylinders, ambulance, emergency light, stretchers etc.
6.5
Management of Training & Supervision
6.5.1
Systematic and well organised training programme on industrial safety, fire safety & first aid should be available to cater needs of all categories of workers. Due consideration should be given on the training and supervision of contract workers who are unskilled and illiterate through pre-job briefings for better communication between the supervisors and workers about the job instructions, job hazards and safety measures to be taken.
6.6
Safety in Material Handling
6.6.1
No lifting machine shall be taken in to use unless it has been tested and all parts have been thoroughly examined by a Competent Person. This will help in finding out design & installation defects in the lifting machine such as rubbing of ropes against any other parts of lifting machine, mechanical locking arrangement between the rail track and the wheel sets of the tower cranes etc.
6.6.2
Thorough inspection & load testing of the tower cranes, mobile cranes and EOT crane should be done by a Competent Person at least once in every twelve months and this record should be maintained properly.
6.6.3
Some times dumpers filled with stones are unloaded in the feed hoppers in reverse direction hitting the guard plate to create jerk on dumpers. The practice of hitting the guard plate in reverse to unload the dumpers fully should be discontinued. Proper engineering design and methods should be applied for unloading the dumpers in the feed hopper area of primary crusher. Path of earth moving machinery should be assessed prior to deployment for use.
56
Proceedings of National Symposium on Industrial and Fire Safety 2006
6.6.4
Only authorised persons who are well trained and experienced in operation shall operate cranes. Except operator, no other person should be allowed to sit on the forklift, as there is no designed provision for sitting other than driver. Checklist for checking the vehicle condition and healthiness should be prepared and followed.
6.6.5
A mobile crane should be operated so that none of its parts can approach live electric lines closer than 3m. Suitable barricading arrangement should be made at both the sides of such electric lines for the safe access of the mobile cranes at such places.
6.7
Electrical Safety Aspects
6.7.1
Proper approach should be provided to the electrical panels and rubber mats should be provided in front of them. Provision of first aid fire fighting equipment like CO2 or dry powder extinguishers shall be made available at electrical equipments.
6.7.2
Clearance for the temporary electric wiring shall be obtained from the Competent Person. Electrical wires / cables shall be properly dressed and adequately protected when laid on floor which may have to be crossed over by construction machinery or by workmen. The cable trenches shall be covered with non-combustible materials or barricaded properly.
6.7.3
Earth leakage protective devices such as ELCB or earth fault relay should be connected in the electrical installation.
6.7.4
Emergency pull cord and stop switches should be provided to all the conveyor systems used in the batching plant.
6.7.5
Adequate emergency lighting arrangements either fixed or portable should be provided for all the working areas at the construction site at night to facilitate safe access to workers to approach and leave the work area.
6.7.6
Periodic inspection and maintenance should be carried out for the portable power tools for electrical insulation, earthing and integrity etc. Damaged / improperly assembled portable power tools should not be used by the persons. It should be ensured that all the tools used by their workmen are safe to use.
6.7.7
Persons working on electrical supply line or apparatus should be authorised by Competent Authority.
7. Conclusion The construction safety has been the cause and concern to the developing countries. It was found that the numbers of injuries resulting into fatalities are comparatively higher at the construction activities. It is observed that one lost time injury takes place amongst 475 employees working at construction sites and amongst 875 employees working at operating units. Number of fatalities and man-days lost are at around 8 times more at construction sites than operating units. Our concept on Foundation for Fatality (Major Injury) among Minor Injuries reveals that 35 minor injuries (lost time or reported injuries) have laid foundation of 1 fatality (major injury) at operating units and 11 minor injuries (lost time or reported injuries) have laid foundation of 1 fatality (major injury) at construction units. Let us not forget that minor injuries set a foundation for a major injury.
Present Status and Improvement of Industrial Safety at Construction Sites
57
It is evident that fall of persons & objects from height are the major contributors for the injuries and higher severity. It can be interpreted that hazardous conditions are generated due to unsafe working conditions & practices followed while working at height. Meticulously planned and organized safety activities are the backbone to prevent and control work place hazards. Top management and line management should be committed to ensure safe working conditions and practices. Efforts of constructor and the regulator should go hand in hand, in inculcating safe working culture. We hope that if the precautions highlighted in this paper are taken care of and the suggestions to control the injuries, subsequent fatalities and man-days lost are followed then present status of industrial safety at construction sites will certainly be improved.
8. References [1] Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (BOCWA, 1996) [2] Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Rules, 1998 (BOCWR) [3] The Factories Act, 1948 (as amended in 1987) [4] Atomic Energy (Factories) Rules, 1996. [5] Chairman, AERBs Notification issued on November 29, 2004 specifying minimum safety precautions needed at any plant or site. [6] The Indian Electricity Act, 2003 [7] The Indian Electricity Rules, 2005 [8] The Gas Cylinder Rules, 2004 [9] Regulatory Inspection Reports of AERB [10] Industrial Safety Statistics Reports of Department of Atomic Energy Units from 1998 to 2005 [11] Industrial Safety Chronicle (Vol.No.XXXVI January March 2006) published by the National Safety Council. * * * * *
Abstract This paper deals with the comparison of injury statistics of the construction sites and operating units of the power generating atomic energy installations. Injury statistics described in the tables & shown in few graphs reveals that the number of injuries, fatalities and man-days lost are comparatively higher at the construction sites as compared to operating units. Number of fatalities and man-days lost are around 8 times more at construction units than operating units, which poses a great challenge to industrial safety at construction sites. On an average, it is observed that every year one lost time injury takes place amongst 475 employees at construction units and amongst 875 employees at operating units. Comparing the number of minor injuries (lost time injuries/reported injuries) and major injuries (fatalities) occurred at operating units and at construction units, we can conclude that on an average 35 minor injuries have laid foundation of 1 major injury at operating units and 11 minor injuries have laid foundation of 1 major injury at construction units. It is evident that fall of persons & fall of objects from height are the major contributors for the injuries and high severity. Few safety precautions are highlighted in this paper in the form of suggestions to control the injuries and subsequent severity and to improve the industrial safety status at construction sites.
1. Introduction The progress of any country is measured in terms of development. Construction activities are the key to any development process, be it industrial, economic or social. As per Construction Industry Development Council (CIDC) Country Report 2005-06, annual turnover of the construction industry is around Rs. 3921 billion which is 6.2% to national GDP and providing employment to around 33 million workers, involving 4.7% engineers, 2.5% technicians & foreman, 15.3% skilled labours and 73.1% unskilled workers. From the above data it is clear that majority of the workers are unskilled and deployed at construction activities. As the duration of every construction activities at site is short and dynamic, the job of construction worker is temporary and migratory in nature. Construction work at a project site is carried out by number of contractors and their subcontractors. When construction work at site is in full swing, various activities are carried out simultaneously at different locations and at different elevations. Work of construction is carried out in more than one shift and even during late hours of night. When construction work is in progress the location of job and activities are dynamic and go on changing frequently posing unplanned hazards. The Construction Action Programme (CAP) of the International Labour Organisation (ILO) has specified that the poor record of the construction industry on occupational safety & health as one of the key problems and a cause
Present Status and Improvement of Industrial Safety at Construction Sites
47
of concern. This paper is being published taking into account this aspect and the increased number of loss time injuries & fatalities at construction activities as compared with operating units of the power generating atomic energy installations.
2. Applicable Legislations for Construction Activities Occupier has to comply with applicable legislation in his pursuit to minimise & control the injuries / damages, to the human being / equipment at construction works. Earlier, there were few legislations applicable for construction activities in India and those were skewed. In order to make comprehensive safety legislations, Government of India has enacted the following Act / Rules to safeguard construction workers (in addition to all other applicable Acts / Rules) : -
Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (BOCWA, 1996) which came in to effect from 1st March, 1996.
-
Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Rules, 1998 (BOCWR) which came in to effect from 11th November, 1998.
3. Present Scenario of Injury Statistics at Construction & Operating Units of Power Generating Atomic Energy Installations A comparative study of the injury statistics of some of the operating and the construction units of power generating atomic energy installations over the period of eight years has been carried out. The findings are as follows : Table : 1
2000 1999 1998 Total
Man Hours Worked
No. of Employees
No. of Man Days Lost
No. of Fatal Injuries
No. of Lost Time Injuries
Operating Units Man Hours Worked
No. of Employees
No. of Man Days Lost
No. of Fatal Injuries
Year 2005 2004 2003 2002 2001
No. of Lost Time Injuries
Construction Units
35 33 45 37 49
9 3 3 5 2
54975 20832 20219 34703 16569
26037 24383 21457 16648 10036
85506285 82834540 74919283 54457242 31440356
5 1 10 9 16
0 1 0 0 0
90 6000 252 149 274
12275 11857 13757 14228 11447
30053421 30785534 34611691 35937817 27947773
46 30 13 288
3 0 1 26
18909 579 6263 173049
11031 13640 13777 137009
26491384 32745560 21300000 409694650
15 16 33 105
0 0 2 3
237 1481 12642 21125
8747 9583 9599 91493
21846360 23856352 24231562 229270510
Proceedings of National Symposium on Industrial and Fire Safety 2006
Injury Trend Construction Units
Operating Units
60
Injuries
50 40 30 20 10 2005
2004
2003
2002
2001
2000
1999
1998
0
Year
Fig. 1.
Fatality Trend 10 8 6 4 2
Year Construction Units
Operating Units
Fig. 2.
2005
2004
2003
2002
2001
2000
1999
0 1998
Fatalities
48
Present Status and Improvement of Industrial Safety at Construction Sites
Trend in Man Days Lost
Man Days Lost
60000 50000 40000 30000 20000 10000 0 1998
1999
2000
2001
2002
2003
2004
2005
Year Construction Units
Operating Units
Fig. 3.
Trend in Employees 30000
Employees
25000 20000 15000 10000 5000 0 1998
1999
2000
2001
2002
2003
2004
Year Construction Units
Fig. 4.
Operating Units
2005
49
50
Proceedings of National Symposium on Industrial and Fire Safety 2006
Man Hours Worked
Trend in Man Hours Worked 90000000 80000000 70000000 60000000 50000000 40000000 30000000 20000000 10000000 0 1998
1999
2000
2001
2002
2003
2004
2005
Year Projects under construction
Operating Units
Fig. 5. It is found that the number of injuries, fatalities, man-days lost, number of employees and man hours worked are comparatively higher at the construction activities than operating units. Number of fatalities and man-days lost are at around 8 times more at construction sites than operating units in 8 years period. Hence, this possess a great challenge to industrial safety at construction sites Overall injuries, fatalities and man-days lost are in decreasing trend in this 8 year period in operating units. However, overall injuries, fatalities and man-days lost are in increasing trend at construction units. During the period of 8 years, 88.98% employees are increased at construction sites, whereas 27.87% employees are increased at operating units. This indicates that there is three fold increase in employees at construction units than operating units. As the number of employees are increased the Man Hours Worked (MHW) are also increased from about 2 crores to 8.5 crores at construction sites and from about 2.5 crores to 3 crores at operating units. At present, Man Hours Worked are 2.85 times more at projects under construction as compared to operating units. On an average every year one lost time injury takes place amongst 475 employees at construction activities and amongst 875 employees at Operating units.
Present Status and Improvement of Industrial Safety at Construction Sites
51
4. Concept on Foundation for Fatality (Major Injury) among Minor Injuries at Operating Units and Construction Units of Power Generating Atomic Energy Installations It was felt necessary to study and correlate the significance of the minor injury with respect to the occurrence of major injury. Exhaustive data with regard to first aid injuries and near miss incidents is not available. The compiled data on minor injuries (lost time or reported injuries) and major injuries (fatalities) that occurred at construction sites & operating units of power generating atomic energy installations for the last eight years period was available as indicated in Table No.1. Efforts were made to establish the relationship between Minor Injuries & Major Injuries. From the data it is seen that 3 fatalities occurred among 105 lost time injuries / reported injuries at operating units, which reveals that on an average 35 minor injuries (lost time or reported injuries) have laid down the foundation for 1 fatality (major injury) at operating units. However, at construction units, 26 fatalities occurred among 288 lost time injuries / reported injuries, which reveals that on an average 11 minor injuries (lost time or reported injuries) have laid down foundation for 1 fatality (major injury) at construction units. This relationship is described in following figures A, B and C.
Major Injuries
Major Injuries 26
3
288
105
(A)
(B)
Construction Units
Operating Units
Minor Injuries
Minor Injuries
Construction Units
Operating Units 11
Minor Injuries
1
35
Fatal
(C)
Fig. 7. Foundation for fatality
Minor Injuries
52
Proceedings of National Symposium on Industrial and Fire Safety 2006
Number of injuries at operating units are less as compared to construction activities because of following major aspects : -
Well established operating or manufacturing systems
-
Adequate, qualified and properly trained manpower
-
Involvement of management & their commitment at all levels (Top, Middle and Lower Management).
Number of injuries and subsequent fatalities at construction sites are more as compared to operating units because of following major reasons : -
Dynamic work situations & make-shift work practices
-
Inadequate, unskilled and improperly trained manpower
-
Because of inadequate and improper supervision there is less involvement & commitment of middle and lower management
-
Lack of proper coordination and communication between the departmental & contractors personnel.
-
Three fold increase in manpower at construction sites.
5. Comparison of Types of Accidents at Construction Sites of Power Generating Atomic Energy Installations Table 2
Type of Accidents at Construction Sites
1999 2000 2001
2002 2003 2004 2005 Total
Fall of Person
12
10
14
10
16
10
17
89
Fall of Object
1
15
14
14
11
9
9
73
Struck by Object
9
9
14
9
8
4
2
55
Caught in or between Object Over-exertion or wrong Movement Exposure to Extreme Temperature
2
6
4
4
5
4
2
27
0
1
1
0
0
0
0
2
3
2
1
0
2
3
0
11
Exposure to Electricity
2
2
0
0
3
1
5
13
Exposure to Harmful Substance
1
1
1
0
0
1
0
4
Explosion
0
0
0
0
0
1
0
1
30
46
49
37
45
33
35
275
Total
Present Status and Improvement of Industrial Safety at Construction Sites
53
Injuries
Type of Accidents 18 16 14 12 10 8 6 4 2 0 1999
2000
2001
2002
2003
2004
2005
Year Fall of Person
Fall of Object
Struck by Object
Caught in or between Object Fig. 8.
Study of injury statistics on construction sites for seven years from 1999 to 2005 shows that number of injuries and subsequent severity of these injuries resulted in fatalities because of majority of injuries are due to fall of persons and fall of objects from height. Out of 275 injuries 89 injuries (32%) are due to fall of persons and 73 injuries (26%) are due to fall of objects. This clearly indicates that much more concentration and attention is required towards working at height to control subsequent injuries & their severity. Other types of accidents leading to injuries are struck by objects (20%), caught in or between object (10%), exposure to electricity (5%) and exposure to extreme temperature (4%) etc.
6. Suggestions for Improvement in Safety Management & Engineering of Working Areas During regulatory inspections we had visited many construction sites and observed some generic and specific inadequacies in safety management & engineering practices at different working areas. Based on some major and frequently observed unsafe conditions and unsafe acts, following suggestions are highlighted to control the injuries and consequences like fatalities, man-days lost to improve the industrial safety status at construction sites.
6.1 6.1.1
Safety Organization & Management Commitments Construction site should have adequate and qualified Safety Officers & Safety Supervisors for their work.
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Proceedings of National Symposium on Industrial and Fire Safety 2006
6.1.2
Workers participation in safety management should be encouraged by constitution of the Sectional Safety Committees for all Sections. The committees shall meet once in month to discuss and ensure health and safety of all employees and the neighborhood.
6.1.3
Specific works like working at height, work at confined spaces, electrical works etc. should be controlled by Safety Work Permit system.
6.1.4
Good engineering practices like Job Hazard Analysis should be carried out for specific & selected activities. Such practices should be followed at various work areas.
6.2
Industrial Hazard Control
6.2.1
As the maximum number of injuries at construction activities are due to fall of persons, fall of objects and struck by object, the personal protective equipment such as safety belt, helmet and safety shoes should be provided to all employees and their use should be strictly enforced by administrative measure.
6.2.2
All potentially dangerous & rotating parts such as flywheels of stone crushers and the rollers of the belt conveyors in the batching plant should be adequately guarded to prevent trapping of body parts / clothing of working personnel.
6.2.3
Floor opening should be either properly covered or provided with guard railing around it. Arrangement of rod bending facility and extreme end points of floor opening at higher elevation from where there is possibility of fall of persons should be provided with adequate guard railing. Considering the fall height provisions such as safety belt, nylon net, working platform with proper width should be enforced at the working at height.
6.2.4
Proper access should be provided for scaffolds and ladders used at various working areas. All scaffolds before use shall be examined by the Engineer-In-Charge of construction activities. Ladders should be qualified with the statutory requirements and should be inspected regularly and repaired immediately. No ladder with defective or missing rungs shall be used.
6.2.5
During the excavation proper shoring and bracing should be done to prevent sliding of excavated material over the persons working in the deep trench. Excavated trenches should be properly barricaded.
6.3
Fire Hazard Control
6.3.1
An approved fire fighting & protection system should be decided upon and installed as the construction activities go on progressing.
6.3.2
Hot work should be controlled and carried out only with proper safety precautions.
6.3.3
Welding cable shall be in good condition. It shall not lie on wet surface nor shall it pass through water or across the passage.
6.3.4
All gas cylinders should be provided with protective cap to their valves and proper chaining arrangement. Pressure gauges of the cylinders should be in healthy condition.
Present Status and Improvement of Industrial Safety at Construction Sites
55
6.3.5
Sufficient number of fire extinguishers shall be placed at strategic points. The testing of fire extinguishers should be done periodically to ensure that the extinguishers are in usable condition.
6.4
Industrial Hygiene & Occupational Health
6.4.1
High noise areas should be identified and noise level measurement should be carried out periodically for such areas. Proper engineering measures, if possible, should be implemented to bring down the noise at appropriate & acceptable levels. Use of suitable PPE such as earplugs and earmuffs should strictly be enforced in these areas to minimise the impact of high noise level.
6.4.2
The measurement of illumination level should be carried out periodically at various working areas and adequately improved. Person should not be allowed to work at a place having total darkness.
6.4.3
Adequate ventilation shall be provided at confined spaces & various work areas where there are chances of fumes/dusts being gathered. However, work at confined spaces should be carried out under the Safety Work Permit system.
6.4.4
First aid centre should be adequately manned & functional during the working hours at the construction sites. It should be equipped with an oxygen cylinders, ambulance, emergency light, stretchers etc.
6.5
Management of Training & Supervision
6.5.1
Systematic and well organised training programme on industrial safety, fire safety & first aid should be available to cater needs of all categories of workers. Due consideration should be given on the training and supervision of contract workers who are unskilled and illiterate through pre-job briefings for better communication between the supervisors and workers about the job instructions, job hazards and safety measures to be taken.
6.6
Safety in Material Handling
6.6.1
No lifting machine shall be taken in to use unless it has been tested and all parts have been thoroughly examined by a Competent Person. This will help in finding out design & installation defects in the lifting machine such as rubbing of ropes against any other parts of lifting machine, mechanical locking arrangement between the rail track and the wheel sets of the tower cranes etc.
6.6.2
Thorough inspection & load testing of the tower cranes, mobile cranes and EOT crane should be done by a Competent Person at least once in every twelve months and this record should be maintained properly.
6.6.3
Some times dumpers filled with stones are unloaded in the feed hoppers in reverse direction hitting the guard plate to create jerk on dumpers. The practice of hitting the guard plate in reverse to unload the dumpers fully should be discontinued. Proper engineering design and methods should be applied for unloading the dumpers in the feed hopper area of primary crusher. Path of earth moving machinery should be assessed prior to deployment for use.
56
Proceedings of National Symposium on Industrial and Fire Safety 2006
6.6.4
Only authorised persons who are well trained and experienced in operation shall operate cranes. Except operator, no other person should be allowed to sit on the forklift, as there is no designed provision for sitting other than driver. Checklist for checking the vehicle condition and healthiness should be prepared and followed.
6.6.5
A mobile crane should be operated so that none of its parts can approach live electric lines closer than 3m. Suitable barricading arrangement should be made at both the sides of such electric lines for the safe access of the mobile cranes at such places.
6.7
Electrical Safety Aspects
6.7.1
Proper approach should be provided to the electrical panels and rubber mats should be provided in front of them. Provision of first aid fire fighting equipment like CO2 or dry powder extinguishers shall be made available at electrical equipments.
6.7.2
Clearance for the temporary electric wiring shall be obtained from the Competent Person. Electrical wires / cables shall be properly dressed and adequately protected when laid on floor which may have to be crossed over by construction machinery or by workmen. The cable trenches shall be covered with non-combustible materials or barricaded properly.
6.7.3
Earth leakage protective devices such as ELCB or earth fault relay should be connected in the electrical installation.
6.7.4
Emergency pull cord and stop switches should be provided to all the conveyor systems used in the batching plant.
6.7.5
Adequate emergency lighting arrangements either fixed or portable should be provided for all the working areas at the construction site at night to facilitate safe access to workers to approach and leave the work area.
6.7.6
Periodic inspection and maintenance should be carried out for the portable power tools for electrical insulation, earthing and integrity etc. Damaged / improperly assembled portable power tools should not be used by the persons. It should be ensured that all the tools used by their workmen are safe to use.
6.7.7
Persons working on electrical supply line or apparatus should be authorised by Competent Authority.
7. Conclusion The construction safety has been the cause and concern to the developing countries. It was found that the numbers of injuries resulting into fatalities are comparatively higher at the construction activities. It is observed that one lost time injury takes place amongst 475 employees working at construction sites and amongst 875 employees working at operating units. Number of fatalities and man-days lost are at around 8 times more at construction sites than operating units. Our concept on Foundation for Fatality (Major Injury) among Minor Injuries reveals that 35 minor injuries (lost time or reported injuries) have laid foundation of 1 fatality (major injury) at operating units and 11 minor injuries (lost time or reported injuries) have laid foundation of 1 fatality (major injury) at construction units. Let us not forget that minor injuries set a foundation for a major injury.
Present Status and Improvement of Industrial Safety at Construction Sites
57
It is evident that fall of persons & objects from height are the major contributors for the injuries and higher severity. It can be interpreted that hazardous conditions are generated due to unsafe working conditions & practices followed while working at height. Meticulously planned and organized safety activities are the backbone to prevent and control work place hazards. Top management and line management should be committed to ensure safe working conditions and practices. Efforts of constructor and the regulator should go hand in hand, in inculcating safe working culture. We hope that if the precautions highlighted in this paper are taken care of and the suggestions to control the injuries, subsequent fatalities and man-days lost are followed then present status of industrial safety at construction sites will certainly be improved.
8. References [1] Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (BOCWA, 1996) [2] Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Rules, 1998 (BOCWR) [3] The Factories Act, 1948 (as amended in 1987) [4] Atomic Energy (Factories) Rules, 1996. [5] Chairman, AERBs Notification issued on November 29, 2004 specifying minimum safety precautions needed at any plant or site. [6] The Indian Electricity Act, 2003 [7] The Indian Electricity Rules, 2005 [8] The Gas Cylinder Rules, 2004 [9] Regulatory Inspection Reports of AERB [10] Industrial Safety Statistics Reports of Department of Atomic Energy Units from 1998 to 2005 [11] Industrial Safety Chronicle (Vol.No.XXXVI January March 2006) published by the National Safety Council. * * * * *
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