SAFETY MANAGEMENT STUDY

HAZARD IDENTIFICATION AND RISK ASSESSMENT - (HIRA) www.safetymgmtstudy.com

S. No. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES

ACTIVITY - 1: BRICK WORKS

1 Storage of bricks 1. Height above 1.5 M 1. Fall of bricks 1. Restrict height of storage to 1.5M
2. Improper Storage 2. Personal Injury 2. Adopt cross tier system of storage.
2 Transportation of bricks to the 1. Unsecured bricks 1. Breakage of bricks 1. Ensure bricks carried are properly secured
site 2. Rough and uneven Road. 2. Personnel injury. 2. Defensive driving.
3 Unloading bricks 1. Fall of bricks 1. Personnel injury 1. Safe handling
2. W rong lifting method. 2. Back pain. 2. Education of correct posture.
4 Shifting bricks to the building site 1. Use of defective dumper 1. Damage to dumper 1. Use serviced dumper
by dumper 2. Mis-operation. 2. Tilting of dumper. 2. Deploy trained operator
3. Operate slowly and carefully on rough road
4. Provide trained banksmen.
5 Shifting bricks, cement mortar, 1. Defective wheelbarrow 1. Overturning of wheelbarrow 1. Use good serviceable wheel barrow
concrete etc., manually, (wheel 2. Loosing balance due to uneven / 2. Personnel injury. 2. Use planks wherever necessary
borrow) loose surface 3. Be cautious.
3. Absent mindedness 4. Concentrate on Job
4. Hurry. 5. Know your surroundings
1. Improper handling of cement bags. 1. Back pain 1. Follow ergonomics
Preparation of cement mortar 2. Skin allergy 2. Use of adequate PPE
and placing of bricks with 1.Evolution of cement dust at work 1. Dust allergy to the workmen 1. Use of adequate PPE
cement. place 2. Eye/Skin injury.
6 2.Splashing of cement mixture.
7 Shifting of cement mortar by 1. Defective dumper 1. Damage to dumper 1. Use serviced dumper
dumper 2. Mis-operation. 2. Tilting of dumper 2. Deploy experienced operator.

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ACTIVITY - 2: CONCRETE CHIPPING
1 Chipping 1. Bad condition of tools 1. Personnel injury 1. Do not use defective tools. Select the right tool for the job.
2. Foreign particles 2. Eye injury 2. Use adequate PPE.
3. Tripping hazard 3. Maintain good house keeping.
4. Remove debris immediately.

ACTIVITY - 3: CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER.

1 Dismantling concrete 1. Fall of Jack hammer. 1. Injury. 1. Hold firm.
(foundation) 2. Vibration. 2. Prolonged exposure causes 2. Secure chisel firm to jack.
occupational disease called white 3. Rotation of work force to avoid prolonged exposure.
finger
ACTIVITY - 4: CONCRETING.
1 Concreting 1. Air pollution by cement. 1. May affect Respiratory System. 1. Wear respirators or cover mouth and nose with wet cloth.
2. Handling of ingradients. 2. Hands may get injured. 2. Use gloves and other PPE.
3. Protruding reinforced rods. 3. Feet may get injured. 3. Use Safety shoes.
4. Earthing of electrical mixers, 4. Can cause electrocution/ 4. Provide platform with wooden planking above reinforcement for
vibrators etc. not done. asphyxiation. movement of workers.
5. Falling of materials from height. 5. Persons may get injured. 5. Ensure earthing of equipments and proper functioning of
6. Continuous pouring of by same 6. Causes tiredness of workers and electrical circuit before commencement of work .
gang. may lead to accident. 6. Use hard hats.
7. Revolving of concrete mixer/ 7. Parts of body or clothes may get 7. Remove surplus material immediately from work place.
vibrators entrapped. 8. Ensure lighting arrangement during night hours.
9. Insist on shift pattern .
10. Provide adequate rest to workers between subsequent pours.
11 .Allow only mixer with hooper.
12. Provide safety cages around moving motors .
13. Ensure proper mechanical locking of vibrator.

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 2 Super- structure 1. Air pollution by cement. 1. Shuttering /props may collapse and 1. Use PPE like goves, shoes, helmets,etc.
2. Handling of ingradients. prove fatal. 2. Avoid usage of make-shift tools.
3. Protruding reinforced rods.
4. Earthing of electrical mixers,
vibrators etc. not done.
5. Falling of materials from height.
6. Continuous pouring of by same
gang.
7. Revolving of concrete mixer/
vibrators
8. Deflection in props or shuttering
material

3 Access to workplace 1. Passage to work place 1. Improperly tied and designed 1. Ensure the stability and strength of passage before
props/planks may collapse. commencement of the work.
2. Do not overload or stand under the passage.
ACTIVITY - 5: CONCRETE MIXTURE OPERATION
1 Deployment of concerte pump 1. Poor mechanical condition of the 1. Failure of equipment. 1. Use good serviced equipment .
equation. 2. Accident /personal injury 2. Deploy only licenced operators.
2. Unauthorised operation 3. Engage banksman.
2 Batching plant. Truck Mixer. 1.Poor mechanical condition of the 1. Failure of equipment. 1. Use good serviceable equipment.
Cement bulk carrier. equipment. 2. Accident /personal injury 2. Deploy only licenced operators.
2. Unauthorised Operation 3. Engage Banksman.
3 Deployment of concerte mixture. 1. Improper placement of mixer 1. Tilting of mixure. 1. Ensure concrete mixer is placed on even surface with proper
machine on uneven surface . 2. Damage to concrete mixer. pegs.
2. Mis-operation. 3. Electrical shock. 4.Fire hazard . 2. Check for proper electrical connections and insulation.
3. Loose contact with electric 5. Personnel injury. 3. Keep adequate fire extinguishers.
connections. 6. Unwanted movement of concrete 4. Proper guards at all rotating parts of machinery.
4. Rotating parts of machine. truck. 5. Position the mixer machine to disperse smoke easily into
5. Unblocked wheels of concrete 7. Mis- operation and injury to crew. atmosphere.
mixer. 8. Breathing problems. 6. Clean the mixer machine after the concreting is over.
6. Improper coordination among crew
members.
7. Smoke from the exhaust.

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 S. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES
No.
ACTIVITY - 6: MANUAL EXCAVATION
1 Piling Work 1. Failure of pile- driving equipment . 1. Can hurt people . 1. Inspect Piling rigs and pulley bricks before the beginning of each shift.
2. Noise pollution. 2. Can cause deafness and 2. Use personal protective equipment like ear plugs, muffs, etc.
3. Extruding rods/ casing . psychological imbalance. 3. Barricade the area and install sign boards.
4. Working in the vicinity of 'Live- 3. Can hurt people. 4. Keep sufficient distance from Live Electricity as per IS code.
Electricity ' 4. Can cause electrocution 5. Shut off the supply, if possible.
/Asphyxiation

2 Pit Excavation upto 3m 1. Falling into pit. 1. Personal injury. 1. Provide guide rails/ barricade with warning signal.
2. Earth collapse. 2. Suffocation / Breathlessness. 2. Provide atleast two entries/ exits.
3. Contact with buried electric cables. 3. Buried. 3. Provide escape ladder.
4. Gas / Oil Pipelines 4. Electrocution. 4. Provide suitable size of shoring and strutting if required .
5. Explosion 5. Keep soil heaps away from edge equivalent to 1.5m or depth of
pit whichever is more.
6. Don't allow vehicles to operate too close to excavated areas .
Maintain atleast 2m distance from edge of cut..
7. Maintain sufficient angle of repose. Provide slope not less than
1:1 and suitable bench of 0.5m width at every 1.5m depth of
excavation in all soils except hard rock.
8. Battering/Benching the sides.
9. Obtain permission from competent authorities , prior to
excavation , if required.
10. Locate the position of buried utililty by referring to plant
drawings.
11. Start digging manually to locate the exact position of buried
utility and thereafter use mechanical means.

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3 Pit excavation beyond 3m. 1. Falling into pit. 1. Personal injury. 1. Prevent ingress of water
2. Earth collapse. 2. Suffocation / Breathlessness. 2. Provide ring buoys.
3. Contact with buried electric cables. 3. Buried. 3. Identify and provide suitable dewatering pump or well point system.
4. Gas / Oil Pipelines 4. Electrocution. 4. Obtain prior approval of excavation method from local authorities, if
3. Flooding due to excessive rain/ 5. Explosion required.
underground water. 6. Can cause drowning situation . 5. Use under-pining method .
4. Digging in the vicinity of the existing 7. Building / structure may collapse . 6. Barricade the excavated area with proper lighting arrangements..
building / structure . 8. Loss of health and wealth. 7. Maintain atleast 2m distance from edge of cut and use stop bricks to
5. Movement of vehicles / equipments 9. May cause cave-in or slides. prevent over-run .
close to the edge of cut. 10. Persons may get buried. 8. Strengthen shoring and strutting.

4 Rock excavation by blasting 1. Improper handling of explosives. 1. May prove fatal. 1. Ensure proper storage, handling and carrying of explosives by
2. Uncontrolled explosion. 2.. May cause severe injuries or prove trained personnel.
3. Scattering of stone pieces in fatal. 2. Comply with the applicable explosive acts and rules.
atmosphere. 3. Can hurt people . 3. Allow only authorized persons to perform blasting operations.
4. Entrapping of animals / persons . 4. May cause severe injuries 4. Smoking and open flame are to be strictly prohibited.
5. Misfire 5. May explode suddenly. 5. Use PPEs like gloves, goggles, face mask, etc.
5. Barricade the area with red flags and blow siren before blasting .
6. Do not return to site for atleast 20min. or unless announced safe
by designated person.

5 Narrow deep excavations for 1. Frequent cave-in or slides. 1. May cause cave-in or slides.. 1. Battering / benching of sides .
pipelines, etc. 2. Flooding due to Hydrostatic testing 2. Persons may get buried. 2. Provide escape ladders.
3. May cause severe injuries or prove 3. Bail out accumulated water.
fatal. 4. Maintain adequate ventilation .
4. May arise drowning situation

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ACTIVITY - 7: MECHANICAL EXCAVATION
1 Excavation using machinery 1. Defective machinery 1. Damage to the machinery 1. Adhere to Permit to Work System if applicable.
2. Mis-operation 2. Damage to underground electrical, 2. Check machine thoroughly before starting the job.
3. Inadvertent operation telecom cables and water services. 3. Use good and serviced machines.
4. Working near the edge of 3. Fall of machinery into the pit. 4. Look for route markers.
excavation 4. Pipe lines rupture/explosion injury. 5. Make trial pits and expose underground cables, if any.
5. Working near utilities. 5. Shock/Fatality 6. Look for warning tapes, cable covering mats concrete saddles
6. Working near overhead lines. 6. Fatal injury and padding.
7. Fall of heavy objects Stone, 7. Lung complaints 7. Use cable detectors.
boulder, soil etc. into excavated pit. 8. Eye injuries. 8. Adhere strictly to manual excavation in case underground cables
8. Fall of persons into the pits. 9. Hit injuries. are present.
9. Dust. 10. Hearing impairment. 9. Follow safety procedure.
10. Congested work site, too many 11. Injury due to hit or collision. 10. Operate machinery, keeping safe distance to avoid excavation
persons working in the pits or 12. Hit and damage to overhead area landside.
trenches. structure. 11. Deploy trained banks man.
11.Noise during rock breaking, heavy 12. Keep away from the edge of the excavation.
equipment operation. 13. Provide barrier away from the edge of excavation.
14. Provide sign boards and blinking lights.
15. Edge of excavation shall be 0.5 m away from highpressure
lines.
16. Keep 1.5 m away from overhead LT lines.
17. Use only approved equipment and competent operators.
18. No entry into the pit during excavation.
19. Keep removed earth at least 1m away from the pit.
20. Provide shuttering/shoring.

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 21. Remove the excavated earth immediately.
22. Do not keep heavy objects on the edge of the pit.
23. Provide barricading with warning signals ( warning light at night)
24. Provide proper ladder to get into the pits.
25. Provide walkway for lengthy trenches.
26. Use dust mask and goggles.
27. Allow only minimum number of persons to work at the same
time.
28. Train for safe manual working procedures.
29. Provide adequate emergency access always.
30. Use earplugs or earmuffs.
31. Provide trained banksman.
32. Keep distance of minimum 5m between two equipment while in
use.
33. Use only approved equipment and employ competent operators.
34.Keep safe overhead distance.
35. Observe special permits wherever required.
36. Strictly adhere to banksmen's signals and directions.

2 Incomplete excavation. 1. Un-noticed hazard area. 1. Fall of persons/animals into the pit. 1. Impart proper instruction to all workmen.
2. Improper barricading. 2. 2. Proper demarcation around the pit.
3. Bad weather. 3. Fall of machinery into pit. 3. Keep sign board "Danger".
4. Landslide due to weather effect 4. Barricade pits / trenches.

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ACTIVITY - 8: ROCK BREAKING
1 Rock excavation using 1. Jolts to operator. 1. Ill health. 1. Employ trained operator with license.
pneumatic equipment, rock 2. Obstruction to vision between 2. Damage, injury to facilities and 2. Avoid applying excessive force to hammer to avert jolting.
breaker, excavators. operator and banksman. people 3. Banksman to stand in direct view with operator.
3. Flying Projectiles. 3. Injury/Damage to asset. 4. Extreme care to prevent projectiles flying from hammer point.
4. Noise. 4. Hearing impairment. 5. Do not operate the hammer if window cabin or shield is not in
5. Dust. 5. Plumonary disorders. place.
6. Excavated Trench 6. Fall of material, equipment, persons 6. Use ear muff / plug.
and animals 7. Use dust mask / Balaclava.
8. Barricade the area with warning sign.
9. Ensure overnight safety.
10. Provide ladder for deep pits.

2 Removal of Hydraulic Hammer 1. Hydraulic pressure jet 1. Loss of Hydraulic oil. 1. Disconnect Hydraulic hose only after closing pressure and return
2. Environmental impact line stop valves.
3 Laying hammer down 1. Fall. 1. Physical injury & back pain. 1. Position the hammer horizontal on wooden block and remove
pins by gentle tapping.
4 W orking near overhead lines 1. Fall of hammer on nearby facilities. 1. Damage to Hammer chisel. 1. Employ trained and licensed operator.
and pressure lines 2. Overhead lines. 2. Physical injury. 2. Careful operation.
3. Hitting, stricking, reversing 3. Damage to assets. 3. Edge of excavation shall be 0.5m away from heigh-pressure
incidents. 4. Shock. pipelines.
5. Fatal injury 4. Keep 1.5 m away from overlhead LT lines.
5. Strict adherence to conditions stipulated by excavation work
permit.
6. Keep adequate signboards and barricade the area.
7. Keep work force 5m away from Rock Breaker.
8. Strict adherence to Banks man's instructions.

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 S. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES
No.
ACTIVITY - 9: PLASTERING
1 Plastering/ Grouting 1. Inhalation of cement dust. 1. Bronchial disease 1. Wear respiratory protection.
2. Absorption of cement 2. Irritation 2. Wear safety goggles and coverall.
3. Ingestion. 3. Prolonged exposure causes 3. Wash hands before taking food 4.Take shower after reaching
dermatitis. camp.
4. Gastro-intestinal disorders.
ACTIVITY - 10: SHUTTERING AND SHORING
1 Shuttering / Handling of wooden 1. Protruding nails. 1. Personal injury. 1. Avoid Protrusion/projection of sharp edges.
planks and supports. 2. Unsafe / Improper handling. 2. Tripping/Slipping hazard. 2. Secure the load properly.
3. Improper house keeping 3. See that there is no strain on back.
2 Cutting wood to required size. 1. Misuse of cutting device. 1. Hand injury . 1. Deploy trained carpenter.
2. Fall of tools & wood from height. 2. Improper cutting resulting in material
loss.
3. Personnel injury.
3 Preparation of shuttering on 1. Flying nails while hammering. 1. Eye injury. 1. Wear safety goggles.
ground. 2. Use of loose hammer. 2. Flying of hammer head resulting in 2. Ensure that hammer handle is properly wedged and hammer is in
personnel injury good condition.
3. Keep persons away from hammering area.
4 Erection of shuttering. 1. Fall of shuttering 1. Physical injury & back pain. 1. Erection should be done standing over firm supports.
5 Erection of shuttering on height. 1. Fall of person or shutter. 1. Personal injury 1. Use approved scaffolding.
2. Fall of loose materials. 2. Damage to the shutter. 2. Do not keep away loose material on platform.
3. Loss of materials. 3. Deploy experienced workers.
6 De-shuttering & De- shoring 1. Fall of shuttering. 1. Injury to persons. 1. Deploy experience workers.
2. Protruding nails. 2. Keep and alert third party persons to be away from the de-
3. Loose nails on floor. shuttering area.
3. Remove nails and stack shuttering materials properly.
4. Keep all removed nails in one container.
5. Maintain good housekeeping.

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 S. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES
No.
ACTIVITY - 11: WORK ON REBAR
1 Manual bar bending. 1. Defective tools 1. Personnel injury. 1. Do not use sub-standard tools.
2. W rong application of tools. 2. Damage to tools. 2. Ensure usage of right tools for right job.
3. W rong posture. 3. Back pain. 3. Do not push tools while bending.
4. Hold firmly.
5. Adhere to correct and safe posture
2 Bar bending on bending 1. Defective machinery. 1. Personal injury 1. Do not use defective tools.
machine 2. Difference in level between table 2. Damage to the machine. 2. Secure machine and table on level ground.
and machine. 3. Damage to the table. 3. Keep area clear around machine.
3. Improper guard. 4. Misoperatorion. 4. Provide switch for emergency stoppage.
4. Inexperienced operator. 5. Ensure guards are provided on all rotating parts.
6. Hold the bars firmly.
7. Stack bars properly and away from machine.

3 Manual cutting 1. Toppling of chisel. 1. Personal injury. 1. Safe handling of tools.

2. Slippage of bar under tension. 2. Flying bar. 2. Keep hand away from cutting chisel.
3. Hold bar firmly.
4. Ensure safety while operating handle.
4 Binding bar with wire 1. Haphazard placement of steel bar. 1. Personal injury 1. Keep wires initially bend downward.

5 Cutting bar by machine 1. Defective machine. 1. Personnel injury. 1. Do not use defective tools.
2. Improper guard. 2. Damage to the machinery. 2. Use serviced machine.
3. Loose electrical connections. 3. Personnel injury. 3. Provide stand on both sides of the machine for moving steel.
4. Defective blade. 4. Fire hazard. 4. Provide switch for emergency stoppage of machine.
5. Personnel injury 5. Ensure proper electrical connections.
6. Do not use defective blade.
7. Keep hands away from cutting blade while in operation.

6 Cuting wire by tools. 1. Defective tools. 1. Personal injury. 1. Use proper binding.
2. Damage of tools. 2. Take exta care while walking around the work site
7 Manual placement of bar. 1. Loose binding of reinforcement . 1. Slippage of binding steel 1. Ensure proper binding .
2. Improper co-ordination. reinforcement. 2. Give proper instructions.
3. Inexperienced persons. 2. Personal injury. 3. Deploy trained and experienced persons.
4. Ensure proper co-ordination among the crew.
5. Avoid sharp edges.

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 S. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES
No.
ACTIVITY - 12 REINFORCEMENT
1 Reinforcement 1. Curtailment and binding of rods. 1. Persons may get injured . 1. Use PPE like gloves, shoes, helmets,etc.
2. Carrying of rods for short distances/ 2. Workers may get injured on their 2. Avoid usage of make-shift tools.
at height. hands and shoulders. 3. Provide suitable pads on shoulders and use safety gloves.
3. Checking of clear distance/ cover 3. Rods may cut or injure the fingers. 4. Tie up rods in easily liftable bundles.
with hands. 4. Persons may get injured and fall 5. Ensure proper staging.
4. Hitting projected rods and standing down . 6. Use measuring devices like tape ,measuring rods,etc.
on cantilever rods. 5. May prove fatal. 7. Use safety shoes and avoid standing unnecessarily on cantilever
6. Protruded rods may hit the persons rods.
8. Avoid wearing of loose cloths.
9. Provide safety nets.

2 Transportation of Rebar 1. Fall of material from height. 1. Personal injury 1. Use red flags / lights at the end s.
2. Hit by protruding bar 2. May prove Fatal 2. Do mot protrude the rods infront of or by the side of the drivers
3. Damage to Material/property cabin.
3. Do not extend the rods 1/3rd. of deck length or 1.5m whichever is
less.

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ACTIVITY - 13 SCAFFOLDING , FORMWORK AND LADDERS
1 Scaffolding , formwork and 1. Person can fall down . 1. Person may sustain severe injuries 1. Provide guard rails for working at height .
ladders 2. Failure of scaffolding material. and prove fatal. 2. Face ladder while climbing and use both hands.
3. Material can fall down 2. Persons working at lower level get 3. Ladder shall exend about 1m above landing for easy access and
injured. tying up purpose.
4. Do not place the ladder against a movable objects and maintain
base at 1/4 ratio of the working length of the ladder.
5. Suspended scaffolds shall not be less than 500mm wide and tied
securely with ropes.
6. No loose planks shall be allowed.
7. Use PPE, like helmets, safety shoes etc.
8. Inspect visually all scaffolding materials for stablity and anchor
with permanent structures.
9. Design scaffolding for max. load carrying capacity.
10. Scaffolding planks shall not be less than 250 mm full thickness
lumber or equivalent. These shall be cleated or secured and must
extend over the end supports by atleast 150 mm and not more than
300mm.
11. Don't overload the scaffolds.
12. Do not join short ladders to make a longer one. Vertical ladders
shall not exceed 6m.
13. Remove excess material and scrap immediately .
14. Carry the tools only in a tool-kit bag.
15. Provide safety nets.

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ACTIVITY - 16: HANDLING OF PORTABLE ELECTRICAL TOOLS
1 W orking with portable electric 1. Damaged cable . 1. Electic shock. 1. Daily check up before start.
tools 2. Defective tool. 2. Spark /shock. 2. Replace defective tools.
3. Loose components (wheel, switch) 3. Hit injury. 3. Proper maintenance.
4. Excess pressure on tool. 4. Accident and injury. 4. Training on proper use & care.
5. Improper handling. 5. Bodily injury. 5. Inspection and corrective action to follow correct handling
6. Non use of PPE. 6. Shock/eye and bodily injuries. procedures.
6. Use adequate PPE (Face shield/googles, gloves)

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ACTIVITY - 17: HANDLING PORTABLE HAND TOOLS
1 W orking with portable hand 1.Defective / damaged tools and tools 1. Accident and bodily injuries. 1. Replacing defective / damaged tools.
tools. without protective handlles. 2. Property damages. 2. Use tools only with protective handles.
2. Improper handling. 3. Training & instruction to use right tool for the right job.
3. Improper storage. 4. Keep tools only in toolboxes.
4. Misuse /abuse. 5. Training & instriction to use right tools for the right job.

ACTIVITY - 18: GAS WELDING

1 Gas welding / cutting / heating. 1. Welding radiates invisible ultraviolet 1. Radiation can damage eyes and 1. Use specified shielding devices and other PPE of correct
and infrared rays. skin. specifications.
2. Improper placement of oxygen and 2. Explosion may occur. 2. Avoid thoriated tungsten electrodes for GTAW .
acetylene cylinders. 3. May cause fire. 3. Move out any leaking cylinder.
3. Leakage /cuts in hoses. 4. Cylinder may burst. 4. Keep trolley for transportation of cylinders and chain them .
4. Opening - up of cylinder. 5. Use flashback arrestors.
5. Welding of tanks, container or pipes 6. Purge regulators immediately and then turn off.
storing flammable liquids. 7. Never use grease or oil on oxygen line connections and copper
fittings on acetylene lines.
8. Inspect regularly gas carrying hoses.
9. Always use red hose for acetylene and other fuel gases and blue
for oxygen.
10. Always stand back from regulator while opening the cylinder.
11. Turn valve slowly to avoid bursting.
12. Cover the lug terminals to prevent short circuiting .
13. Empty & purge them before welding.
14. Never attach the ground cable to tanks, container or pipe
storing flammable liquids.
15. Never use LPG for gas cutting.

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ACTIVITY - 19: ARC WELDING
1 Arc welding 1. Radiation harmful to naked eyes. 1. Welder's cataract. 1.Use welding shield / goggles.
2. Splinters / slag. 3.Toxic flames. 2. Burn injury. 2. Fireproof apron / gloves / screen.
4. Dislocation / fall of job piece due to 3. Lung ailments 3. Ventilation (local or exhaust if possible)
faulty clamping. 4. Dermatitis. 4. Full-sleeved coverall and gloves.
5. Loose connections / Loss of 5. Hit injury / crush injury. 5. Proper clamping system / material handling techniques.
insulation. 6. Electric shock. 6. Use shock proof boots and hand gloves.
6. Flammable gases. 7. Fire / explosion. 7. Provide earthing to the plant.
7. Poor ventilation 8. Asphyxiation. 8. Periodical gas testing.
9. Keep fire extinguisher (DCP/CO ) standby.
2
10. Adequate ventilation.
11. Training & instructions.

ACTIVITY - 20: WORKING IN CONFINED SPACE

1 W orking in confined spaces 1. Suffocation / drowning. 1. Unconsciousness, death. 1. Use respiratory devices, if required.
(tank, vessel, static equipment, 2. Presence of foul smell and toxic 2. Inhalation can pose threat to life. 2. Avoid over crowding inside a confined space.
excavation beyond 3m etc) substances. 3. Person may sustain burn injuries or 3. Provide exhaust fans for ventilation.
3. Ignition/ flame can cause fire. explosion may occur. 4. Do not wear loose clothes, neck ties, etc.
5. Fulfill conditions of the permit.
6. Check for presence of hydrocarbons and oxygen level.
7. Obtain work permit before entering a confined space .
8. Ensure that the connected piping of the equipment which is to be
opened is pressure free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange.

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 9. Check for hydrocarbon and Aromatic compounds before entering
a confined space.
10. Depute one person outside the confined space for continuous
monitoring and for extending help in case of an emergency.
11. Keep the fire extinguishers at hand distance.
12. Remove surplus material and scrap immediately .
13. Do not smoke inside a confined space.
14. Do not allow gas cylinders inside a confined space.
15. Use low voltage (24V) for hand held lighting.
16. Use tools with air motors or electric tools with max. voltage of
24V.
17. Remove all equipments at the end of the day.

ACTIVITY - 21: MATERIAL HANDLING (MANUAL)

1 Material handling (manual) 1. Non-use of PPE. 1. Accident/ injury. 1. Use adequate PPE.
2. Inadequate manpower. 2. Back pain,sprain,etc. 2. provide adequate manpower for lifting of heavy loads.
3. Lack of co-ordination in group 3. Property damage. 3. Training & instructions.
effort. 4. Injury /property damage. 4. Use hand gloves/ packing materials.
4. W rong body posture. 5. Loss of property. 5. Remove protruding nails before handling.
5. Lifting error. 6. Use proper lifting devices for good grip.
6. Sharp edges / corners / projecting 7. Fasten the item properly or use suitable packing
parts / protruding nails. / container.
7. Slippery materials.
8. Loose materials.

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ACTIVITY - 22: MATERIAL HANDLING (MECHANICAL)
1 Material handling with forklift , 1. Lack of knowledge / skills. 1. Accident / injury. 1. Only competent and approved operator shall be deployed for
hiab, crane etc. 2. Defective equipment. 2. Material losses. equipment operations.
3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent person before
4. Overloading. 4. Injury due to accident and property deployment.
5. Untrained opertator. damage. 3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banksmen / rigger.

ACTIVITY - 23: WORK AT HEIGHTS

1 W orking at elevated places. 1. Person can fall down. 1. May sustain sever injuries or prove 1. Provide guard rails/ barricade at the work place.
2. Material can fall down fatal . 2. Use PPE like full body harness, life line, helmets, safety shoes,
2. May hit the scrap/ material stacked etc.
at the ground or in between . 3. Obtain the permit before starting the work at height above 3m.
3. May hit the workers working at lower 4. Fall arrest and safety nets, etc, must be installed.
levels and prove fatal. 5. Provide adequate working space (min.0.6m).
6. Tie / weld working platform with fixed support .
7. Use roof top walk ladder while working on a slopping roofs.
8. Avoid movement on beams.
9. Keep the work place neat and clean.
10. Remove the scrap immediately.
11. Do not throw or drop materials or equipment from height. i.e. do
not bomb materials.
12. All tools to be carried in a tool- kit Bag or on working uniform.
13. Remove scrap from the planks.
14. Ensure wearing of helmet by the workers working at lower
levels.

ACTIVITY - 24: WORKING UNDER CRANE / LIFTING EQUIPMENT.

1 W orking under crane / lifting 1. Working without PPE. 1. Fatality / injury due to fall of loads. 1. Use required PPE.
equipment 2. Failure of slings. 2. Material damage. 2. Use only certified slings as per colour coding.
3. Improper handling. 3. No person to stand under lifted load.
4. Overloading. 4. Follow safe lifting procedures.
5. Defective equipment. 5. Only approved equipment to be used.
6. Lack of awarness. 6. Ensure pronpr servicing.
7. Training to operator and provinding banks man / rigger for
assistance.

ACTIVITY - 25 LOADING / UNLOADING ON TRUCK / TRAILER.

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1 Loading and unloading of 1. Loaded material due to fall. 1. Accident / injury 1. Follow lifting procedure.
materials on trucks 2. Defective equipment. 2. Damage of materials. 3.Damage to 2. Use correct equipment & lifting tackles.
/ trailers. 3. Overloading equipment. 3. Supervision by competent persons.
4. Provide trained banksmen/rigger.
5. Do not jump out from vehicle till clearence is obtained.
6. Proper supervision.
7. Refer to load chart.
8. Use platform ladder for safe access.
9. Never deactivate or deenergise over riding devices on lifting
equipment.

2 Loading near live facilities 1. Live facilities / OH lines etc. 1. Fire 1. Keep Safe distance from Live facilities.
2. Electric shock.
3. Injury.
4. Property Damage

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 S. ACTIVITY HAZARD CONSEQUENCE CONTROL MEASURES
No.
ACTIVITY - 26: MATERIAL HANDLING WITH CRANE
1 Crane positioning 1. Outriggers on soft ground/loose soil 1. Tilting of crane & consequent 1. Outrigger base plates to rest on firm ground or on timber bricks/
damage & loss. steel plates
2 Operating of PTO 1. Operating levers not in neutral 1. Inadvertent operation of crane on 1. Make sure control levers are all in neutral position
position. engagement of PTO
3 Extending outriggers 1. Outriggers not extended fully 1. Tilting of the crane. 1. Extend outrigger fully.
2. Outrigger not locked. 2. Retracting of outriggers & tilting of 2. Lock the outrigger beam.
the crane
5 Passage under OH lines with 1. High tension electric current . 1. Electric shock. 1. No movement with raised boom
raised boom 2. Traveling with load. 2. Fall of load & tilting of crane. 2. Provide Banksman
3. Do not travel with lifted load.
4 Loading operation 1. Side loading / dragging of load. 1. Tilting of the crane due to uneven 1. Lifting only vertically.
2. Overload. load. 2. No dragging of load.
3. Swinging the load. 2. Damage to crane and loss of 3. No overload.
4. Abrupt operation of control levers. materials. 4. No swinging of load.
5. Keeping the load in the elevated 3. Instability & tilting of crane. 5. Operate the levers slowly and smoothly.
position. 4. Jerking, fall of load, hitting person. 6. Do not keep the load in the elevated position.
6. Persons standing below the lifted 5. Fall of load due to mechanical 7. Do not allow any person to be under the load.
load. failures. 8. No movement with raised boom.
6. Fall of load causing human injuries. 9. Provide Banksman.
7. Electric shock. 10. Do not travel with lifted load.
8. Fall of load & tilting of crane.

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ACTIVITY - 28: HANDLING OF GAS CYLINDERS
1 Transporting gas cylinders: 1. Cylinders kept horizontal. 1. Fire and explosion by leakage and 1. Keep charged cylinder only.
* Oxygen 2. Cylinder kept untied property damage. 2. Keep vertically and tie with chain to a fixed structure.
* Acetylene. /unlocked in welding truck 2. Gas leakage due to valve damage. 3. Keep in specially fabricated cage to prevent fall.
* Argon. /mobile welding unit. 3. Human injury by fall of cylinder. 4. Keep valve cap in position during transportation.
* Nitrogen. 3. Valve leakage. 4. Damage to cylinder/valve. 5. Different types of gas cylinders not to be loaded in the same
* LPG. 5. Leakage of gas. vehicle at a time.
6. Only authorized vehicle and specially trained driver shall be
engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked independently on truck to
prevent falling of one cylinder while loading/unloading the other.

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ACTIVITY - 31: ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING
1 Scaffolding erection 1. Improper manual handling. 1. Personal injuries. 1. Train on proper manual lifting procedures.
2. Fall of scaffolding materials. 2. Material damage. 2. Use only tested and certified equipment & lifting tackles.
3. Hitting. 3. Collapse of scaffolding and fall of 3. Erection only by experienced persons under supervision of a
4.Defective lifting equipment / persons. competent person.
improper use. 4. Daily inspection and certification by competent person.
5.Faulty erection. 5. PTW in place.

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2 W orking on scaffolding 1. Defective scaffolding. 1. Injury due to fall. 1. Daily inspection & certification by competent person.
2. Improper use. 2. Training & supervision.
3. Faulty access to platform. 3. Provide access (Ladders or Stairs_ as per specification.
4. Inadequate size of platform. 4. Adequate size as per job requirement.
5. Overloading. 5. No overloading permitted.
6. Faulty / unguarded access 5. Only minimum number of persons allowed to work at a time.
ladder/stairs

3 Dismantling scaffolding 1. Fall of persons. 1. Fatality / injury. 1. Follow dismantling procedures.

2. Fall of scaffolding materials. 2. Do not allow persons to be under the scaffolding structure.
3. Fall of hand tools (hammer etc.) 3. Use PPEs (helmet, gloves)
4. Keep tools in proper holder.

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ACTIVITY - 34: WORKING IN HOT ENVIRONMENT
1 1. Working in hot environment. 1. Heat stress due to failure of thermo- 1. Heat ailments such as heat 1. Drink plenty of cold water.
2. Hot work such as welding, regulatory system of the body. exhausting, heat cramps and heat 2. Intermittent rest under shades.
cutting, heating, cooking, etc. 2. Dehydration due to excess loss of stroke. 3. Eating more vegetables and fruit items.
body fluids. 4. Provide shade for work in static posture (welding).
5. Appropriate PPE to protect body against direct exposure to heat
or hot sun.

ACTIVITY - 35: WORKING IN DUSTY ENVIRONMENT

1 W orking in dust 1. Dust (Inhalation and striking the 1. Lung disorders (silicosis) and eye 1. Sprinkle water to supress dust generation wherever possible.
eye) injury. 2. Use PPE (dust mask, goggles)

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ACTIVITY - 37: STAY IN CAMPS
1 Staying in residential camps 1. Biological hazards (Malarial 1. Ill health. 1. Prompt disposal of wastes, concealment of drainage.
mosquitoes, contaminated water / food 2. Use of insecticides.
stuff) 3. Ventilation in living accommodation.
4. Keeping food wastes in garbage bags/closed buckets and prompt
disposal to the food waste to dump yard as per Waste Management
Plan.
5. Dead slow driving in camp premises.
6. No night driving.
7. Extremely cautious against crossing of stray animals.
8. Do not cause harm to any livestock.
9. Obseve warning signals on roads against stray animals.

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ACTIVITY - 38: SLIPS, TRIPS AND FALLS AT WORK PLACE.
1 Moving in the work area. 1. Timbering bricks, wooden planks, steel 1. Bodily injury due to fall of persons , 1. Remove all timber bricks, planks, pipe pieces etc immediately after use
rod bits. fall of heavy objects, tools etc. to the designated place.
2. Pipe pieces. 2. Hitting on overhead projections. 2. Do not keep objects / tools etc at heights without safe containment
3. Protruding bolts on concrete against fall.
foundations of pipe supports. 3. Provide barricading with warning tags.
4. Paint tins, polythene papers, electric 4. Provide plastic/soft material cap to projecting pipes and warning tags to
cable/wire insulations, steel wire caution the workers.
insulations, steel wire cuttings, tools & tool 5. Maintain good house keeping by frequent appraisals, supervision,
boxes. inspection, audit and follow up.
5. Overhead projection of pipes.

ACTIVITY - 39: FIRE PREVENTION AND PROTECTION

1 Fire prevention and protection 1. Small fires can become big ones 1. Cause burn injuries and may prove 8. Do not use any sort of elevators for evacuation during fire.
and may spread to the surroundings fatal. 9. Maintain lightening arrestors for elevated structures.
aresa. 2. Complete extinguishment of fire may 10. Stop all electrical motors.
2. Improper selection of Fire not be possible. 11. Move the vehicles from dangerous locations .
extinguishers. 3. Can cause electrocution 12. Remove the load hanging from the crane booms .
3. Short circuiting of electrical system. 13. Remain out of the danger areas.
14. Ensure usage of correct fire extinguisher meant for the specified
fire.
15. Do not attempt to extinguish oil and electric fires with water. Use
foam extinguishers /CO2
/sand.
16.Maintain safe distance of flammable substances from source of
ignition .
17. Restrict the distribution of flammable materials to only min.
necessary amount
18. Construct specifically designed fuel storage facilities.
19. Keep chemicals in cool and dry place away from heat. Ensure
adequate ventilation.
20. Before welding operation , remove or shield the flammable
materials properly.
21. Store flammable materials in stable racks, correctly labeled
preferably with catchment trays.
22. Wipe off the spills immediately .

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ACTIVITY - 40: LAYING ELECTRICAL CABLES
1 Laying out electrical cables 1. Unstable Cable drum. 1. Fatality / service injury due to fall of 1. Cable shall be handled by experienced persons.
(Cable drum handling) 2. W rong position of jack. cable drum or jack. 2. Adopt proper procedure.
3. Inadequate jack / spindle. 2. Injury by hitting / caught in. 3. Use only tested and certified jack and spindle.
4. Defective jack / spindle. 3. Finger injury due to trapping 4. Keep fingers away from nip points.
5. Rotating parts. between drum / rollers. 5. Use hand gloves.
6. Drum rollers. 4. Serious injury due to slip & fall of 6. Tool box meeting.
7. Pulling in wrong posture. cable. 7. Proper position.
8. Open trench. 5. Loss of cable. 8. Trained person.
9. Theft. 9. Use cable roller.
10. Planning
11. Keep cable-laid trenches backfilled before leaving site.

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ACTIVITY - 44: ELECTRICAL INSTALLATION AND USAGE
1 Electrical installation works 1. Short circuiting. 1. Can cause Electrocution or Fire. 1. Use rubberized hand gloves and other PPE.
2. Overloading of Electrical System 2. Bursting of system can occur which 2. Don’t lay wires above ground or under carpets, mats or door
leads to fire ways. Lay cables overhead or buried.
3. Allow only licensed electricians to perform on electrical facilities.
4. Use only approved and insulated wires or cables.
5. Don't place bare wire ends in a sockets. Use Plugtops.
6. Ensure earthing of all machines and equipments.
7. Do not use damaged cords and avoid temporary connections
.8. Use spark proof / flame proof type field distribution boxes.
9. Do not allow open / bare connection.
10. Provide all connections through ELCB.
11. Protect electrical cables / equipment 's from water and naked
flames.
12. Check all connections before energizing.
13. Display voltage and current ratings prominently with 'Danger'
signs.
14. Ensure approved cable size, voltage, grade and type.
15. Switch off the electrical utilities when not in use.
16. Do not allow unauthorized connections.
17. Ensure proper grid wise distribution of power.
18. Do not lay unarmoured cable directly on ground, wall, roof or
trees.
19. Maintain atleast 3 m distance from HT cables .
20. All temporary cables should be laid atleast 750 mm below
ground on 100 mm fine sand overlying by brick soling.
21. Provide cable route markers indicating the type and depth of
cable at intervals not exceeding 30 m and at the diversions/
termination.

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ACTIVITY - 46: DRIVING / OPERATING VEHICLES & EQUIPMENTS
1 Driving /operating vehicles/ 1. Lack of knowledge and skill. 1. Fatality / injury. 1. Only authorized persons to be deployed for driving / equipment
equipment 2. Untrained drivers / operators. 2. Loss of property / material. operation.
3. Defective vehicles / equipments. 3. Damage to equipment. 2. Training / refresher training to drivers / operators.
4. Over speed / overload. 3. Use of appropriate vehicles /equipments.
4. Inspection & supervision.
5. Provide banksmen as appropriate.

2 Driving on graded roads 1. Loose surface, erosion, pot holes. 1. Injury / fatalities due to accidents. 1. Provide speed limiters.
2. Use tyres with a minimum of 2 mm tread.
3. Drive with dipped headlights and high intensity lights on.

3 Speed driving 1. Crossing the speed limits (Rash 1. Personnel injury 1. Obey speed limits and traffic rules strictly.
driving) 2. Always expect the unexpected and be a defensive driver.
3. Use seat belts/ helmets.
4. Blow horn at intersections and during overtaking operations.
5. Maintain the vehicle in good condition.
6. Do not overtake on curves , bridges and slopes.

4 Driving in adverse condition 1. Adverse weather condition. 1. Personnel injury. 1. Read the road ahead and drive to the left.
2. Falling objects/ Mechanical failure 2. May prove fatal 2. Keep the wind screen and lights clean .
3. Do not turn at speed.
4. Recognize the hazard, understand the defense and act correctly
in time.
5. Ensure effective braking system, adequate visibility for the
drivers, reverse horn.
6. Proper maintenance of the vehicle as per manufacturer's
instructions.

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 5 Drunken Driving 1. Consuming alcohol before and 1. Accident 1. Alcohol and driving do not mix well. Either choose alcohol or
during the driving operation 2. Personal injury driving.
2. If you have a choice between hitting a fixed object or an on-
coming vehicle ,hit the fixed object.
3. Quit the steering at once and become a passenger. Otherwise
take sufficient rest and then drive.
4. Do not force the driver to drive fast and round the clock.
5. Do not day dream while driving.

ACTIVITY - 47: PARKING OF VEHICLES IN PARKING AREA

1 Vehicle parking in designated 1. Improper parking. 1. Rolling of vehicle resulting in fatality 1. Follow parking procedure.
area 2. Uneven surface. / injury. 2. Level ground for parking.
3. Defective hand brake. 2. Damage to vehicle / properties / live 3. Proper Hand brake.
4. Absence of wheel choke. facilities nearby. 4. Wheel chokes in position.
5. Non / Partial application of hand 5. Gear engagement.
brake.

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Page 34 of 51
ACTIVITY - 50: OPERATION OF COMPACTOR
1 1. Starting by pulling up with 1. Inadvertent contact with vibrator. 1. Accidents. 1. Pull the string gently avoiding contact or hit against compactor or
string. 2. Rotating parts. 2. Damage. nearby personal.
2. Running compactor 3. Fall. 2. Guarding.
3. Hold firm and move slowly.
ACTIVITY - 51: OPERATION OF CRANE
1 Operation of Power Take Off 1. Inadvertent movement of crane 1. Accidents. 1. Make sure PTO levers are in neutral position
(PTO) 2. Damage.
2 Positioning outrigger. 1.Outriggers can sink in soft ground. 1. Lifting of vehicle. 1. Crane must be set on firm ground. On soft ground place strong wooden
2. Improper extinction of the 2. Tilting of vehicle. bricks or steel plates on ground and set outriggers on them.
outriggers. 3. Physical injury. 2. Extend the outrigger beam fully as far as possible during operation.
3. Improper locking of outriggers. 4. Equipment damage. 3. Be sure to lock the outrigger beams with lock pins.
5. Material damage.

3 Locking operation. 1. Side loading or dragging of loads 1. Cause serious damage to 1. Avoid side looking or dragging loads.
will exert extra load on crane. equipment . 2. Strict adherence to SWL.
2. Excess load. 2. Crane becomes unstable & causes 3. Ensure crane is installed with safety limits.
3. Abrupt load. accident. 4. Move the levers in a slow manner.
4. Careless 3. Electrocution 5. Attention on operation.
6. Do not allow workers to stand within the working radius.

4 Inspection of winch rope. 1. Damaged or less turns of winch 1. Cause serious accidents 1. Inspect rope for any damage or twist and replace in case of any
rope. damage.
5 Travelling 1.Travelling with lifted load. 1. Unstability . 1. While travelling, disengage PTO.
2. Travelling with engaged PTO. 2. Causes serious accidents
6 Signals 1. Improper signs 1.Leads to confusion and accidents. 1. Competent banksman to be detailed for signals.

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ACTIVITY - 53: OPERATION OF VIBRATOR
1 Starting by pulling up with string 1. Inadvertant contact with vibrator. 1. Injury. 1. Pull the string gently avoiding contact or hit against vibtator or
2. Rotating parts. Kick back of hose. 2. Contact with body. nearby personnel.
3. Cement splash. 3. Damage. 2. Guarding.
4. Fall of vibrator into excavation 4. Burn hazard. 3. Hold the hose firm while vibration is in use.
concreting location. 4. Keep in safe place.
5. Fire hazard 5. Keep away from naked flames.
6. Keep DCP Fire Extinguisher ready.

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ACTIVITY - 60: HANDLING AND LIFTING EUIPMENTS (GENERAL)
1 Handling and lifting equipments 1. Failure of load lifting and moving 1. Can cause accident and prove fatal. 1. Avoid standing under the lifted load and within the operating radius of
equipment. 2. Can cause electrocution and fire cranes.
2. Overloading of lifting equipments. 2. Check periodically oil, brakes, gears, horns and tyre pressureS.
3. Overloading electrical wires 3. Check size and condition of all chain pulley bricks, slings, U-clamps, D-
shackles, wire ropes etc.
4. Allow crane to move only on hard, firm and levelled ground .
5. Allow lifting slings as short as possible and check gunny packing's at the
friction points.
6. Do not allow crane to lift its boom while moving.
7. Install Safe Load Indicator.
8. Ensure load test certification by competent authority.
9. Safe lifting capacity of winches written on them shall be followed.
10. The max. safe working load shall be marked on all the lifting
equipments.
11. Check the weight of columns and other heavy items painted on them
and accordingly decide about the crane capacity, boom and angle of
erection .
12. Allow only trained operators and riggers during crane operation.
13. Do not allow the boom or other parts of crane to come within 3m
reach of overhead HT cables.
14. Hook and load being lifted shall preferably remain in full visibility of
Riggers and Operators.

ACTIVITY - 61: GRIT BLASTING

1 Compressor operation 1. Bursting of piping. 1. May cause injury and prove fatal. 1. Prepare procedure and obtain client's approval.
2. Collapse of tanks. 2. Provide separate gauge for measurement monitoring of pressur
3. Tanks flying off. in the pump,piping and equipment .
3. Check the calibration status of all pressure gauge.
4. Take dial reading at suitable defined intervals and ensure most of
them fall with in desirable range
5. Provide safety relief valve.( set at pressure slightly higher than
test pressure ) while testing .
6. Ensure necessary precautions, stepwise increase in pressure ,
tightening of bolts/nuts, grouting, etc before and during testing.
7. Ensure compressor is tested & certified by competant person
8. Compressor to be operated by trained person only.
9.Location of operating valve to be with in the visibility of oprator
working in side the booth. 10.Air filter to be provided to avoid the
water trap & to be clean periodically.

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4.Generation of high noise level Loss of hearing capacity 1.Provide PPE to workmen working arround. 2.Measure the noise
level periodically to monitor. 3.Health check up of employees at
periodically.
4.Isolate the facility so minimum number of persons are exposed to
hazard.
5.Generation of dust 1. Ill health. 1. Provide proper PPE to workmen working arround.
2. Barricating the total by providing curtain arround.
3. Health check up to be done periodically to monitor the health.

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 2 Loading/Operating of hopper 1. Generation of dust. 1.Ill health. 1. Provide proper PPE to workmen working arround.
2. Injury due to bursting of the flange 2. Barricat the total area by providing curtain arround the booth
coupling. opening.
3. Health check up to be done periodically to monitor the health.
4.Work to be done by the trained operator only.

3 Application of nozzle. 1. Bursting of joint 1. Physical Injury. 1. Nozzle to be operated only by experienced & qualified operator.
2. Flying of nozzale & hitting persons 2. Eye Injury 2. Periodical check for equipment to be carried out for any wear &
3. Bursting of hosses. 4.Hit by nozzle 3. Ill health. tear of the hosses for it's serviceability.
in the eyes

4 Use of compress air 1.Generation of noise. 2. Genration 1.Phisical Injury. 1.Work to be done by the trained operator only. 2.Periodical
of dust 2.Loss of hearing capacity 3.Ill Health maintenance schedule to be achare. 3.Air filter to be checked up
periodically for it's proper operation.
4.Provide proper PPE to workmen working arround.

5 Grit filteration. 1. Generation of dust. 1. Physical Injury.(hand injury) 1.Work to be done by the trained operator only. 2.PPE to be provided.e.g.
2. Eye Injury hand gloves;safety goggals etc.
3. Ill health. 3.Filteration to be done inside the booth only which is to be perfectly
covered perfectly.
ACTIVITY - 62: FABRICATION YARD OPERATIONS
1 Grinding and grinding wheel 1. Absence of tool rest on bench 1. Eye / face injury 1. Use proper PPE. ( Face shield )
replacing. grinder. 2. Hand injury 2. Mount the tool rest on both sides.
2. More gap between the wheel and 3. Gap more than 3mm is unsafe.
tool rest of bench grinder. 4. Use grinding wheel of correct size.
3. Improper/wrong size grinding 5. Training & instruction.
wheel. 6. Provide fire extinguisher.
4. Excess pressure on wheel. 7. Proper tightening of wheel.
5. Breakage of wheel. 8. Use of correct size spacer washers.

2 W orking with portable electric 1. Damaged cable . 1. Electric shock. 1. Daily check up before start.
tools 2. Defective tool. 2. Spark/shock. 2. Replace defective tools.
3. Loose components (wheel, switch) 3. Physical injury. 3. Proper maintenance.
4. Excess pressure on tool. 4. Training on proper use & care.
5. Improper handling. 5. Inspection and corrective action to follow correct handling
6. Non use of PPE. procedures.
6. Use adequate PPE (Face shield/goggles, gloves)

3 Gas welding / cutting / heating. 1. Backfiring. 1. Fatality / burn injury, fire / explosion. 1. Work only after wearing PPE.
2. Splashing splinters. 2. Gas leakage due to fall of cylinder 2. Fit flash back arrestor and NRV on both cylinder outlets.
3. Gas leakage. and damage of valves. 3. Use face shield and fire proof gloves.
4. W rong positioning of cylinders. 4. Daily check up before start of work.
5. Presence of flammable gases. 5. Keep cylinders in trolleys or chain to some firm structure to
prevent fall.
6. Gas testing before start of work.
7. Employ competent and trained welder.
8. Provide windshield.

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4 Arc welding 1. Radiation harmful to naked eyes. 1. Welder's cataract. 1.Use welding shield / goggles.
2. Splinters / slag. 3.Toxic flames. 2. Burn injury. 2. Fireproof apron / gloves / screen.
4. Loose connections / Loss of 3. Lung ailments 3. Ventilation (local or exhaust if possible)
insulation. 4. Electric shock. 4. Full-sleeved coverall and gloves.
5. Flammable gases. 5. Fire / explosion. 5. Proper clamping system / material handling techniques.
6. Poor ventilation 6. Asphyxiation. 6. Use shock proof boots and hand gloves.
7. Provide earthing to the plant.
8. Periodical gas testing.
9. Keep fire extinguisher (DCP/CO ) standby.
2
10. Adequate ventilation.
11. Training & instructions.

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5 Material handling (manual) 1. Lack of co-ordination in group 1. Back pain,sprain,etc. 1. Training & instructions.
effort. 2. Body Injury 2. Use hand gloves/ packing materials.
2. W rong body posture. 3. Remove protruding nails before handling.
3. Lifting error. 4. Use proper lifting devices for good grip.
4. Sharp edges/corners/projecting 5. Fasten the item properly or use suitable packing
parts/protruding nails. / container.
5. Slippery materials.
6. Loose materials.

6 Material handling with forklift / 1. Lack of knowledge / skills. 1. Body injury. 1. Only trained and approved operator shall be deployed for
crane etc. 2. Defective equipment. 2. Material losses. equipment operations.
3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent person before
4. Overloading. deployment.
3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banksmen / rigger.

7 Transporting gas cylinders: 1. Falling of cylinders 2. Gas leakage due to valve damage. 1. Keep charged cylinder only.
* Oxygen 2. Explosion 3. Human injury by fall of cylinder. 2. Keep vertically and tie with chain to a fixed structure.
* Acetylene. 4. Fire / body injury due to explosion 3. Keep in specially fabricated cage to prevent fall.
* Argon. 4. Keep valve cap in position during transportation.
* Nitrogen. 5. Different types of gas cylinders not to be loaded in the same
* LPG. vehicle at a time.
6. Only authorized vehicle and specially trained driver shall be
engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked independently on truck to
prevent falling of one cylinder while loading/unloading the other.

8 Laying out electrical cables 1. Unstable Cable drum. 1. Body injury due to fall of cable drum 1. Cable shall be handled by experienced persons.
(Cable drum handling) 2. W rong position of jack. or jack. 2. Adopt proper procedure.
3. Inadequate jack / spindle. 2. Injury by hitting / caught in. 3. Use only tested and certified jack and spindle.
4. Rotating parts. 3. Finger injury due to trapping 4. Keep fingers away from nip points.
5. Drum rollers. between drum / rollers. 5. Use hand gloves.
6. Pulling in wrong posture. 6. Use cable roller.
7. Open trench. 7. Keep cable-laid trenches backfilled before leaving site.

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ACTIVITY - 64: OFFICE WORK
2 Use of VDUs 1.Glaring from screen 2.Body 1. Eye injury. 1. Maintain safe distance & height from the screen at the time of
stress due to bad ergonomic 2. Bach ach. working.
3.Electrical shock due to loose 3. Electricutation 2. Install a screen guard to filter the unwanted rays.
electrical connection 3. Provision of furniture e.g. working table ,chair etc suitable for
comfertable working.
3 Illumination at all working 1. Inadequqte illumination. 1.Eye strain. 1.Provide proper PPE to workmen working arround.
stations. 2. Headach. 2. Barricating the total by providing curtain arround.
3. Adequate reflector to be provided at all light fitting as a antiglaring
arrangement to improve the comfert.
4.Work to be
done by the trained operator only.

4 Ventilation 1.Inadequate ventilation. 2.Electrical 1. Physical strain. 1. Maitain adequate level of ventilation with proper temprature.
hazard. 2. Mental strain. 2. Adherance to perioddical maintenance schedule. 3.Ensure to
3. Fire. switch off the ventilation as & when it is not required.

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4 Mental work load. 1.Mental depression 1.Mentally effected. 1.Allow person to take break to releive the mental stresses at
differant interval of time.
2.Pre employment heath check to be conducted arround.

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