SISS SLM Compressed

Tamil Nadu Open University
School of Continuing Education
Short-Term Course in Industrial

Safety and Security
SISS-1 & P1: Industrial Safety and

Security
Name of Programme: Short-Term Course in Industrial Safety and
Security
Course Code with Title: SISS-1 & P1: Industrial Safety and Security
Dr. P. Thiyagarajan
Curriculum Design:
Professor & Director
R. Meenambigai
Assistant Professor
Dr. I. Ambeth
Assistant Professor
Tamil Nadu Open University, Chennai.
R. Meenambigai
Content Editor and
Assistant Professor
Course Coordinator:
Tamil Nadu Open University, Chennai.
June 2022 (First Edition)
ISBN No.:
Total no. of pages: 149
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obtained from the University Office at 577, Anna Salai, Saidapet, Chennai-600 015 [or]
www.tnou.ac.in
@ TNOU, 2022, “Industrial Safety and Security” is made available under a

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Short-Term Course in Industrial Safety and Security
Unit No. Title Page

No.
SISS-T: Industrial Safety and Security-Theory
Unit-1 Principles of Safety Management 4
Unit-2 Industrial Safety, Health and Environment Act 19
Unit-3 Fire and Electrical Safety 46
Unit-4 Material Handling and Safety 74
Unit-5 Safety in Construction 95
SISS-P: Industrial Safety and Security-Practical
Exercise-1 Accident Investigation – Report format 111
Exercise-2 Handling and operation of Fire Extinguishers – 113

Type A, B, C and D
Exercise-3 Handling of Hydrant pipes and hoses 116
Exercise-4 Handling and operation of Foam Generators 120
Exercise-5 Conduction of Fire Drill 124
Exercise-6 Handling of LPG and other gas cylinders - Safety 130
Exercise-7 Safety measures, inspection checks for 135

conveyors and cranes
Exercise-8 Safety measures, inspection checks for 143

excavation
1
Course Introduction
The Short-Term Course in Industrial Safety and Security covers both

theoretical and practical aspects of the topic under discussion. The Course
consists of five units for theoretical aspects and eight exercises to cover the
practical component. The details of content covered in the theoretical part
SISS-1 are as follows:
Unit-1: Principles of Safety Management will detail about the Definition of
Industrial Safety, Objectives of Industrial Safety, Industrial Safety Planning,
The impact of Workplace Accidents, Common Causes of Workplace
Accidents, The Best Ways to Prevent Workplace Accidents, Workplace
Safety Training and Meetings.
Unit-2: Industrial Safety, Health and Environment Acts will explain about the
Introduction, List of laws and regulations relating to Safety and Health of
Industrial workers, The Chemical Accidents (Emergency Planning,
Preparedness and Response) Rules, 1996, The Building and other
Construction workers (Regulation of employment and conditions of service)
Act, 1996.
Unit-3: Fire and Electrical Safety explains the Fire Triangle, Classification of
Fuels, Air-Pressurized Water Extinguishers, Carbon Dioxide Extinguishers,
Dry Chemical Extinguishers, Rules for Fighting Fires, How to Use a Fire
Extinguisher, Fire Alarms and its types, Fire Hazard Analyses and Fire Risk
Assessments and Electrical Safety - Protection system: Fuse, circuit
breakers and overload relays and earth fault protection.
Unit-4: Material Handling and Safety details the Workers Safety, Material
Handling, Manual Material Handling, Mechanized Material Handling
Equipment’s and Accessories.
Unit-5: Safety in Construction describes the Introduction to construction
site, Construction Hazards, Material Handling – Manual and by Equipment,
Excavations, Asbestos, Electricity and Site Security, Ladder safety.
The Practical Component of the Short-Term Course in Industrial Safety and
Security SISS-P covers the following eight exercises:
Exercise-1 Accident Investigation – Report format

Exercise-2 Handling and operation of Fire Extinguishers – Type A, B,
C and D
2
Exercise-3 Handling of Hydrant pipes and hoses
Exercise-4 Handling and operation of Foam Generators
Exercise-5 Conduction of Fire Drill
Exercise-6 Handling of LPG and other gas cylinders - Safety
Exercise-7 Safety measures, inspection checks for conveyors and
cranes
Exercise-8 Safety measures, inspection checks for excavation
3
Unit-1
Principles of Safety Management
Structure
Overview
Objectives
1.1. Definition
1.2. Objectives of Industrial Safety

1.3. Industrial Safety Planning
1.4. The impact of Workplace Accidents
1.5. Common Causes of Workplace Accidents

1.6. The Best Ways to Prevent Workplace Accidents
1.7. Workplace Safety Training and Meetings
Check Your Progress

Let Us Sum Up
Answers to Check Your Progress
Overview
In this Unit you will learn about the Definition of Industrial Safety, Objectives
of Industrial Safety, Industrial Safety Planning, The impact of Workplace
Accidents, Common Causes of Workplace Accidents, The Best Ways to
Prevent Workplace Accidents, Workplace Safety Training and Meetings.
Objectives
After learning this Unit, you will be able to understand about:

 Definition of Industrial Safety
 Objectives of Industrial Safety
 Industrial Safety Planning

 The impact of Workplace Accidents
 Common Causes of Workplace Accidents
4
 The Best Ways to Prevent Workplace Accidents
 Workplace Safety Training and Meetings
1.1. Definition
Industrial safety is defined as policies and protections put in place to ensure

plant and factory worker protection from hazards that could cause injury.
Safety policies put in place by the Occupational Safety & Health
Administration (OSHA) are examples of industrial safety policies.
The system safety concept calls for a risk management strategy based on
identification, analysis of hazards and application of remedial controls using
a systems-based approach.
As per the standard rules, it is mandatory for every industrial organization to
employ a safety officer. This has made safety management a foremost
career option in India and abroad alike. Safety management or industrial
safety which deals with the study of the possibilities of any mishap or
danger, correlated to the health of workers or equipment, chemicals, or
machines in an industry. The objective of an industrial safety manager is to
reduce the chance of risks, accidents.
This is different from traditional safety strategies which rely on control of
conditions and causes of an accident based either on the epidemiological
analysis or as a result of investigation of individual past accidents. The
concept of system safety is useful in demonstrating adequacy of
technologies when difficulties are faced with probabilistic risk analysis.
The underlying principle is one of synergy: a whole is more than sum of its
parts. Systems-based approach to safety requires the application of
scientific, technical and managerial skills to hazard identification, hazard
analysis, and elimination, control, or management of hazards throughout the
life-cycle of a system, program, project or an activity or a product "Hazop" is
one of several techniques available for identification of hazards.
Industrial safety is a broad area of workplace safety, covering a number of
issues and topics, including:
 General safety (issues and concerns that are common across all
industries)
 Site-specific safety issues
 Process and production safety
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 Material safety
 Fire safety
 Electrical safety
 Building and structural safety (including temporary installations)

 Environmental safety
 The Importance of Industrial Safety
Although every workplace and job task carry some safety hazards, industrial
hazards are often higher risk and have the potential to cause severe injury,
extensive property damage, or devastating environmental harm.
Given the highly specialized nature of the work, many of the jobs are carried
out by trained and skilled employees. Workers who sustain lost time injuries
can be difficult to replace, even temporarily. Because of this, injuries can
have significant effects on a company's production output, shipping
schedules, fulfillment, vendor relationships and customer satisfaction. Good
safety practices, then, not only keep workers safe but also help maintain
employee, vendor, and client satisfaction.
1.2. Objectives of Industrial Safety
 Preventing work-related fatalities, disabling injuries, illness, and

damage to machinery or materials
 Ensuring continued production by preventing disruptive incidents
 Reducing workers compensation costs, maintaining lower insurance
rates, and minimizing indirect costs associated with accidents
 Strengthening safety culture and increasing employee morale
 Meeting vendor and client expectations
1.3. Industrial Safety Planning
Industrial safety takes place long before the work begins. In fact, it should
be part of the job planning and site design. Some important early and
ongoing considerations include:
 Plant layout
 Fire prevention systems
 Health and hygiene
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 Safety training
 Alarms and warning systems
 Adequate lighting in work areas and corridors
 Flooring and working areas that are easy to clean and organize
 Insulation
 Signboards and written safety instructions
A company safety policy must be written that is simple and easy to interpret.
It must be incorporated into your overall safety system and communicated
to all employees. If the current safety policy does not outline how
employees are to report hazards, it should be modified to document
appropriate procedures. Once completed, the policy can be communicated
through all types of media: posting on both electronic and hardcopy, bulletin
boards and/or websites, distributing to all employees, and, most importantly,
discussed in daily, weekly, and monthly meetings, and/or other plant-wide
meetings
A positive policy for reporting safety issues affirms your intentions to protect
employees from harassment or reprisal.
Quality has been defined as “doing the right thing at the right time for the
right person and having the best possible result.” Patient safety is simply
defined by the World Health Organization as “the prevention of errors and
adverse effects to patients associated with health care”.
The thousands of industrial accidents every year caused the realization of

the importance of industrial safety with technological advancement in
manufacturing. The dangers of human life are increasing day by day. To
avoid accidents, employees must be aware of industrial safety principles &
danger areas of that industry. The following are some reasons why
Industrial safety is necessary: For the safety of people in their workplaces
for protecting the environment against damage from industrial accidents For
protecting businesses against serious losses from damage to plant and
machinery For eliminating accidents causing work stoppage and production
loss. For creating awareness of the good practices available for the delivery
of effective safety instrumented systems For providing basic training in well-
established techniques for engineering of safety systems For assisting
engineers and technicians to support and participate in the safety systems
activities at their work with good background knowledge of the subject For
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being aware of what can go wrong and how to avoid it Industrial Safety
Precautions on different machines & Hand tools”] Because of safety first
rule, all industrial personals must be trained enough about safety aspects of
man, machines, and material & other infrastructure facilities for avoiding
minor or major accidents. Safety is the first requirement, and every
industrial employee must learn safety measures even before he starts
working on a machine or equipment.
1. Obey Safety Requirements:
One of the main causes of injuries and accidents on the job is failure to
comply with safety regulations. If you are an employer, then be sure to
provide proper safety training for your employees and post warnings and
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instructions throughout the workspace to ensure that your employees know
what they should and shouldn’t be doing. If you are an employee, make
sure you know what the rules are and that you follow them – because even
when a safety precaution seems ridiculous, it’s in place because it has
prevented injury (or death) in the past.
2. Communicate:
Another way to help prevent accidents on the job is to be in constant

communication with other workers in your area. If you are working with
heavy machinery, make sure everyone knows what you’re planning to do. If
you need to walk through a hard hat zone, make sure you talk to someone
and know what work is being done in the area so that you are on the alert.
3. Provide/Get Proper Training:
As an employer, make sure your workers know what they are doing.
Provide proper training to anyone who is going to use heavy machinery,
chemicals, or dangerous products of any kind. As an employee, make sure
you know how to properly use a machine, a chemical, or any other
dangerous product – never assume you can figure it out yourself.
4. Keep Machinery and Equipment in Working Order:
When was the last time your machine got a tune-up? Does it have any parts
that need replacing? Is there damage that you don’t know about? Always
make sure you are using a machine that has been recently inspected and
has received proper maintenance and repairs before you take it out on the
job.
5. Don’t Take Shortcuts:
Faster isn’t always better, especially when safety can be jeopardized. Do

your works the right way and always make sure to keep safety your number
one priority, even if it takes a little longer. You could save a life – possibly
even yours.
To prevent accidents from happening, start with a general awareness and
understanding of the safety risks in your work environment. Then, you’ll
need to pair that knowledge with an action plan for accident prevention to
make sure the potential risks you’ve identified do not introduce harm into
your workplace.
9
1.4. The Impact of Workplace Accidents
Outside of bodily harm, workplace accidents present a number of

challenges for business owners.
First, workplace accidents can lead to a loss of productivity. If a worker is

harmed in the workplace, he or she may have to take time off of work. With
the rest of the team having to pick up the slack, you’re likely to lose the
productivity you would have had with a fully staffed team.
Additionally, such accidents can impact other employees and may cause
them to feel unsafe in their workplace. This can translate to deflated morale
and a loss of motivation, both of which can negatively impact productivity.
Moreover, a business’s negligence that results in an accident or a bodily
injury can have serious financial and legal implications. Workers’
compensation claims may arise, as well as possible litigation. A single
lawsuit can significantly impede business growth and can even drive a
business into bankruptcy.
Preventing accidents and creating a culture of safety awareness are the

best ways to ensure that the above does not happen in your place of
business.
Before discussing how you can identify hazards and mitigate potential
injuries in your workplace, let’s examine some recent statistics on workplace
accidents.
Workplace Accident Statistics:
The most recent data on workplace accidents show that there were 882,730
occupational injuries and illnesses in 2017.
 11% involved overexertion in lifting or lowering.

 64% of bone fractures were from accidents in the service industries.
 62% of slips, trips, and falls were on the same level.
 20% of slips, trips, and falls were from a worker falling between two
or more levels.
 15% of all nonfatal workplace injuries were from workers being
struck by equipment or objects while on the job.
 35% of cases across all industries resulted from sprains, strains, and
tears.
10
 Across all industries, more than 25% of all injuries were caused by
slips, trips, and falls.
1.5. Common Causes of Workplace Accidents
One of the cornerstones of safety awareness is understanding what unique

risks are associated with your work environment. With this aspect of
awareness locked down, you’ll be able to craft proactive solutions for
preventing these accidents.
According to the Centers for Disease Control and Prevention (CDC), slips,
trips, and falls in the workplace are most likely to happen because of:
 Ladders
 Roofs
 Scaffolding
 When assessing the cases reporting these accidents, the CDC

found that:
 20% of falls on the same level are from trips.
 13% of falls on the same level are from slips.

 11% of falls to a lower level occur when someone falls
through a surface or an existing opening.
Even if your job environment does not involve workers interacting with the
leading causes of slips, trips, and falls (like ladders or scaffolding), there are
other areas where these accidents can occur.
When assessing your workplace, be on the lookout for areas or objects that
may increase the likelihood of someone slipping, tripping, or falling. Slips,
trips, and falls can also result from:
 Spills
 Slippery surfaces
 Obstructions
 Broken equipment
 Areas with a lack of safety signage
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1.6. The Best Ways to Prevent Workplace Accidents
The best way to avoid workplace accidents is through a strategic safety

plan. With proactive measures in place, you and your employees can create
a culture of safety and a targeted accident prevention program.
Consider the following tips to bolster your safety efforts:
 Promote safety awareness and education with regular safety

briefings and employee safety training.
 Install proper lighting to create a well-lit and visible jobsite that
makes it easier for your staff to see potential risks and avoid them.
 Communicate safety hazards with adequate signage that clearly

identifies hazardous areas and potential risks like obstacles, spills,
toxic materials, or other hazards.
 Contain spills quickly when they happen, and remember to always

have cleanup equipment readily accessible in your workplace.
 Routinely check for safety hazards, like spills or obstacles.
 Install proper ventilation to prevent toxic chemicals or other foreign

particles from being inhaled by your employees.
 Enforce proper attire that’s necessary for accident prevention, like
hard hats or slip-resistant shoes.
12
Organisations investigate business upsets because they are required to by
law or their own company standards, or the public or shareholders expect it.
But, whatever the motivation, the goal is to identify why the incident
happened and to take action to reduce the risk of future incidents.
Investigations often find that similar scenarios have occurred previously but,
for a variety of reasons, did not result in serious consequences. This is
increasingly recognised in high-risk industries where “near misses” are also
investigated as well as incidents which actually resulted in loss.
A six-step, structured approach to incident investigation helps to ensure that
all the causes are uncovered and addressed by appropriate actions.
STEP 1 – IMMEDIATE ACTION
In the event of an incident, immediate action to be taken may include

making the area safe, preserving the scene and notifying relevant parties.
The investigation begins even at this early stage, by collecting perishable
evidence, e.g. CCTV tapes, samples.
13
STEP 2 – PLAN THE INVESTIGATION
Planning ensures that the investigation is systematic and complete. What

resources will be required? Who will be involved? How long will the
investigation take? For severe or complex incidents, an investigation team
will be more effective than a single investigator.
STEP 3 – DATA COLLECTION
Information about the incident is available from numerous sources, not only
people involved or witnesses to the event, but also from equipment,
documents and the scene of the incident.
STEP 4 – DATA ANALYSIS
Typically, an incident is not just a single event, but a chain of events. The
sequence of events needs to be understood before identifying why the
incident happened.
STEP 5 – CORRECTIVE ACTIONS
Many investigations make the mistake of raising actions which deal only
with the direct causes – a quick fix, putting last-lines-of- defence back in
place. By ignoring the root and underlying causes, not only do they miss an
opportunity to reduce the risk of recurrence of the incident, but they also
leave open the possibility that other, dissimilar incidents may also occur,
arising from the same, common root cause.
When asking why, we need to identify the root and underlying causes, as
well as the direct causes. Failures and mistakes don’t just happen by
themselves; organisations allow error-enforcing environments that
encourage direct causes to develop and persist. Such environments, and
the basic management failings behind them, are the root causes – the
ultimate source of the incident.
While human error plays a part in the majority of incidents, people are not
generally stupid, lazy, forgetful or wilfully negligent. Human errors occur
because of influencing factors associated with the work, the environment,
an individual’s mental or physical abilities, the organisation and its
management systems. Any investigation which sets out to find someone to
blame is misguided.
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STEP 6 – REPORTING
The investigation is concluded when all outstanding issues have been

closed out and the findings have been communicated so that lessons can
be shared. Communication mechanisms include formal incident
investigation reports, alerts, presentations and meeting topics.
1.7. Workplace Safety Training and Meetings
The Industrial Safety course programme teaches students all practical

aspects of Risk management techniques, Safety management operations,
Monitoring safety and health operations. Improving standard of health of the
employees and enhancing general safety measures.
Workplace training is also known as trade or industry training. Employee
orientation trainings aim at showing new employees how to do their jobs
safely and usefully, but leading companies know that it is essential to go
much further than that.
Workplace safety training is as vital as workplace safety itself. It enables the
management to ensure a safe and healthy work environment. It also helps
the employees to recognize safety hazards and correct them. It enables
them to understand best safety practices and expectations.
Safety training is all the more important for organizations like hospitals and
construction companies that use hazardous materials and equipment.
Safety training is vital for employees or workers with regard to
understanding of safety practices related to their jobs; otherwise, a worker
will find himself/herself at a higher risk for workplace injury, illness or death.
Safety training in modern businesses has become quite unavoidable due to
the following reasons −
 Communications − The growing multiplicity of today's employees
brings a wide variety of languages and customs.
 Computer skills − Computer skills are becoming an essential for

managing administrative and office tasks.
 Customer service − The growing contest in today's worldwide
marketplace makes it grave that employees understand and meet
the needs of customers.
15
 Diversity − Diversity training generally comprises of explanation
about how people have different vista and views, and comprises
techniques to value multiplicity.
 Ethics − Today's society has growing assumptions about corporate

social control. Also, today's various workforces bring a wide variety
of values and significance to the workplace.
 Human relations − The enlarged stresses of today's workplace can

include misunderstandings and dispute.
 Quality initiatives − Initiatives such as Total Quality Management,
Quality Circles, standard, etc., needs basic training about quality
idea, instructions and standards for quality, etc.
 Safety − Safety training is disapproving where working with heavy
equipment, dangerous chemicals, tedious activities, etc., but can
also be useful with real advice for avoiding attacks, etc.
 Sexual harassment − Sexual harassment training generally includes
careful explanation of the organization's policies about sexual
harassment, especially about what are unsuitable behaviors.
Workplace Safety Meetings:
Safety meetings and safety talks are generally thought of as departmental

or team meetings. These repeated meetings, ranging from weekly to
monthly depending upon the conditions, allow the manager or trainer to
evaluate any accidents experienced by members of the group, go over any
unsafe practices observed, acknowledge the requirement for safe work
practices, and to answer any questions that employees may have about
equipment operation or other safety issues. Topics for a safety meeting can
be chosen on the basis of An evaluation of the most recent accidents and
near-misses at the benefits or within the similar industry Post-installation of
new machinery or equipment and their handling Associated corporate safety
goals Any specific subjects that required to be covered from a legal or
insurance standpoint
Proposal from employees, safety inspectors, contractor safety

representatives, insurance representatives, or other knowledgeable
observers
OSHA Training
 Hazard Communication
16
 Ladder Safety
 Fall Protection
 Electrical Safety for Construction: Power Lines and Lockout/Tagout
 Machine Guarding
 Personal Protective Equipment
 Powered Industrial Trucks - Operators Overview
 Preventing Slips, Trips and Falls

 Respiratory Protection
 Scaffold Safety Awarenes
Check Your Progress
Fill in the Blanks:
1. The objective of an industrial _______________ is to reduce the chance

of risks, accidents
2. "Hazop" is one of several techniques available for identification of
_______________.
3. ________________ has been defined as “doing the right thing at the right
time for the right person and having the best possible result.”
4. Across all industries, more than _________% of all injuries were caused
by slips, trips, and falls
5. The best way to avoid workplace accidents is through a strategic
_______________.
6. Workplace training is also known as ______________ training.
Let Us Sum Up
In this Unit you have learnt about the Definition of Industrial Safety,
Objectives of Industrial Safety, Industrial Safety Planning, The impact of
Workplace Accidents, Common Causes of Workplace Accidents, The Best
Ways to Prevent Workplace Accidents, Workplace Safety Training and
Meetings.
17
1. safety manager
2. hazards
3. Quality
4. 25
5. safety plan
6. trade or industry
18
Unit-2
Industrial Safety, Health and Environment Act
Structure
Overview
Objectives
2.1. Introduction
2.2. List of laws and regulations relating to Safety and Health of Industrial
workers
2.3. The Chemical Accidents (Emergency Planning, Preparedness and
Response) Rules, 1996
2.4. The Building and other Construction workers (Regulation of
employment and conditions of service) Act, 1996
Check Your Progress

Let Us Sum Up
Overview
In this Unit you will learn about the Introduction, List of laws and regulations
relating to Safety and Health of Industrial workers, The Chemical Accidents
(Emergency Planning, Preparedness and Response) Rules, 1996, The
Building and other Construction workers (Regulation of employment and
conditions of service) Act, 1996.
Objectives

 Introduction
 List of laws and regulations relating to Safety and Health of Industrial

workers
 The Chemical Accidents (Emergency Planning, Preparedness and
19
 The Building and other Construction workers (Regulation of
employment and conditions of service) Act, 1996.
2.1. Introduction
Environment (E), health (H) and safety (S), EHS is an acronym for the
methodology that studies and implements the practical aspects of protecting
the environment and maintaining health and safety at occupation. In simple
terms it is what organizations must do to make sure that their activities do
not cause harm to anyone. Commonly, quality - quality assurance & quality
control - is adjoined to form the company division known as HSQE.
From a safety standpoint, it involves creating organized efforts and
procedures for identifying workplace hazards and reducing accidents and
exposure to harmful situations and substances. It also includes training of
personnel in accident prevention, accident response, emergency
preparedness, and use of protective clothing and equipment.
Better health at its heart, should have the development of safe, high quality,
and environmentally friendly processes, working practices and systemic
activities that prevent or reduce the risk of harm to people in general,
operators, or patients.
From an environmental standpoint, it involves creating a systematic
approach to complying with environmental regulations, such as managing
waste or air emissions all the way to helping site's reduce the
company's carbon footprint.
Regulatory requirements play an important role in EHS discipline and EHS
managers must identify and understand relevant EHS regulations, the
implications of which must be communicated to executive management so
the company can implement suitable measures. Organizations based in the
United States are subject to EHS regulations in the Code of Federal
Regulations, particularly CFR 29, 40, and 49. Still, EHS management is not
limited to legal compliance and companies should be encouraged to do
more than is required by law, if appropriate.
2.2. List of laws and regulations relating to Safety and Health of

industrial Workers
1. The Factories Act 1948- An Act to consolidate and amend the law
regulating labour in factories
 Model Factories Rules
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 State Factories Rules
2. The Mines Act 1952 – An Act to amend and consolidate the law
relating to the regulation of labour and safety in mines.
 The Mines Rules 1955

 The Metalliferous Mines Regulations, 1961
 The Coal Mines Regulations, 1957
 The Mines Vocational Rules 1966
 The Mines Rescue Rules 1985
3. The Explosives Act 1884 – An Act to regulate the Manufacture,
Possession, Use, sale, Transport, Import and Export of Explosives.
 The Explosive Rules 1983
 The Static and Mobile Pressure Vessels (Unfired) Rules
1981
 The Gas Cylinder Rules 1981
4. The Petroleum Act 1934 – An act to consolidate and amend the
law relating the import, transport, storage, production, refining and
blending of petroleum.
 The Petroleum Rules 1976
 The Calcium Carbide Rules 1987
5. The Indian Electricity Act, 1910- An Act to consolidate the laws
relating to generation, transmission, distribution, trading and use of
electricity and generally for taking measures conducive to
development of electricity industry, promoting competition therein,
protecting interest of consumers and supply of electricity to all areas,
rationalization of electricity tariff, ensuring transparent policies
regarding subsidies, promotion of efficient and environmentally
benign policies, constitution of Central Electricity Authority,
Regulatory Commissions and establishment of Appellate Tribunal
and for matters connected therewith or incidental thereto.
 The Indian Electricity Rules, 1956
6. The Indian Boilers Act, 1923 – An Act to consolidate and amend the
law relating to steam boilers.
 The Indian Boilers Regulations 1950
7. The Environment Protection Act, 1986– An Act to provide for the
protection and improvement of environment and matters connected
therewith.
21
 The Environment Protection Rules, 1986
 The Manufacture Storage and Import of Hazardous
Chemicals Rules, 1989
 The Hazardous Wastes (Management and Handling)
Rules, 1989
 The Bio-Medical Waste (Management and Handling)
Rules, 1998
 The Chemical Accidents (Emergency Planning,
Preparedness and Response) Rules, 1996.
 The Noise Pollution (Regulation & Control) Rules, 2000
8. The Water (Prevention & Control of Pollution) Act, 1974 – An Act
to provide for the prevention and control of water pollution and the
maintaining or restoring of wholesomeness of water, for the
establishment, with a view to carrying out the purposes aforesaid, of
Boards for the prevention and control of water pollution, for
conferring on and assigning to such Boards powers and functions
relating thereto and for matters connected therewith.
 The Water (Prevention & Control of Pollution) Rules, 1975.
9. The Air (Prevention & Control of Pollution) Act 1981 – An Act to
provide for prevention, control and abatement of air pollution, for the
establishment, with a view to carrying out the aforesaid purposes, of
Boards for conferring on and assigning to such Boards powers and
functions relating thereto and for matters connected therewith
 The Air (Prevention & Control of Pollution) Rules 1982
10. The Public Liability Insurance Act 1991– An act to provide for
public liability insurance for the persons affected by accident
occurring while handling any hazardous substance and for matters
connected therewith or incidental thereto.
 The Public Liability Insurance Rules 1991
11. Workmen’s Compensation Act 1923 - An act to provide workmen
and/or their dependents some relief in case of accidents arising out
of and in the course of employment and causing either death or
disablement of workmen.
12. Employees’ State Insurance Act 1948 - An act to provide certain
benefits to employees in case of certain sickness, maternity and
employment injury and to make provisions for certain other matters
in relation thereto.
22
13. Radiation Protection Rules, 1971.
14. Contract Labour (Regulation & Abolition) Act, 1970
An act to regulate the employment of contract labours in certain

establishments and to provide for its abolition in certain
circumstances and for matter connected therewith.
15. The Motors Vehicles Act 1988- An Act to consolidate and amend
the law relating to motor vehicles
 The Central Motor Vehicles Rules 1989 and Motor
Vehicles Rules of respective States
16. The Building and Other Construction Workers (Regulation of
Employment & Conditions of Service) Act,1996 – An Act to
regulate the Employment and conditions of service of building and
other construction workers and to provide for their safety, health
and welfare measures and for other matters connected therewith or
incidental thereto.
 The Building and Other Construction Workers
(Regulation of Employment & Conditions of Service)
Central Rules, 1998.
17. The Standards of Weights & Measure (Enforcement), Act, 1985
18. The Insecticides Act, 1968 - An Act to regulate the import,
manufacture, sale, transport, distribution and use of insecticides
with a view to prevent risk to human beings or animals, and
for matters connected therewith.
19. The Disaster Management Act, 2005 - An Act to provide for the
effective management of disasters and for matters connected
therewith or incidental thereto.
20. The Persons with Disabilities (Equal Opportunities, Protection
of Rights and Full Participation) Act, 1995 - An Act to give effect
to the Proclamation on the Full Participation and Equality of the
People with Disabilities in the Asian and Pacific Region.
23
2.3. The Chemical Accidents (Emergency Planning, Preparedness And
1. Definitions:
In these rules unless the context otherwise requires,:-

"Chemical accident" means an accident involving a fortuitous ,or sudden or
unintended occurrence while handling any hazardous chemicals resulting in
continuous, intermittent or repeated exposure to death, or injury to, any
person or damage to any property but does not include an accident by
reason only of war or radio-activity;
a) "Hazardous chemical" means,-

i) any chemical which satisfies any of the criteria laid down in Part I
of Schedule 1 or is listed in Part 2 of the said schedule;
ii) any chemical listed in Column 2 of Schedule 2;

iii) any chemical listed in Column 2 of Schedule 3;
b) "Industrial activity" includes an operation or process, carried out in an
industrial installation referred to in Schedule - 4 involving or likely to
involve one or more hazardous chemicals;
i) on-site storage or on-site transport which is associated with that
operation or process as the case may be;
ii) isolated storage;
iii) pipeline;
c) "Industrial pocket" means any industrial Zone earmarked by the

Industrial Development Corporation of the State Government or by the
State Government;
d) "Isolated storage" means,- storage of a hazardous chemical other than

storage associated with an installation on the same site specified in
Schedule-4 where that storage involves at least the quantities of that
chemical set out in Schedule-2;
e) "Major Chemical Accident" means - an occurrence including any
particular major emission, fire or explosion involving one or more
hazardous chemicals and resulting from uncontrolled developments in
the course of industrial activity or transportation or due to natural
events leading to serious effects both immediate or delayed , inside or
24
outside the installation likely to cause substantial loss of life and
property including adverse effects on the environment;
f) "Major Accident Hazards (MAH) Installations" - means, isolated
storages and industrial activity at a site, handling (including transport
through carrier or pipeline) of hazardous chemicals equal to or, in
excess of the threshold quantities specified in Column 3 of Schedule 2
and Schedule 3 respectively;
g) "Manufacture, Storage and Import of Hazardous Chemicals Rules"
means - the Manufacture, Storage and Import of Hazardous
Chemicals Rules, 1989, published in the notification of Government of
India in the Ministry of Environment & Forests No.S.O.966(E) dated
27th November 1989;
h) "Off-site Emergency Plan" means - the off-site emergency plan

prepared under rule 14 of the Manufacture, Storage and Import of
Hazardous Chemicals Rules;
i) "Pipeline" means - a pipe (together with any apparatus and works

associated therewith) or system of pipes (together with any apparatus
and works associated therewith) for the conveyance of a hazardous
chemical other than a flammable gas as set out in Column 2 of Part II
of Schedule 1, at a pressure of less than 8 bars absolute;
j) "Site" means,- any location where hazardous chemicals are
manufactured or processed, stored, handled, used, disposed off and
includes the whole of an area under the control of an occupier and
includes pier, jetty or similar structure whether floating or not;
k) "Transport" means,- movement of hazardous chemicals by any means

over land, water or air;
2. Constitution of Central Crisis Group:
a) The Central Government shall constitute a Central Crisis Group for

management of chemical accidents and set up a Crisis Alert System in
accordance with the provisions of Rule-4 within thirty days from the
date of the commencement of these rules.
b) The composition of the Central Crisis Group shall be as specified in
Schedule 5.
c) The Central Crisis Group shall meet at least once in six months and
follow such procedure for transaction of business as it deems fit.
25
d) Notwithstanding anything contained in sub-rule (2), the Central Crisis
Group may co-opt any person whose assistance or advice is
considered useful in performing any of its functions to participate in the
deliberations of any of its meetings.
3. Constitution of Crisis Alert System:
The Central Government shall,:-
a) set up a functional control room at such place as it deems fit;

b) set up an information net working system with the State and district
control rooms;
c) appoint adequate staff and experts to man the functional control

room;
d) publish a list of Major Accident Hazard installations;
e) publish a list of major chemical accidents in chronological order;

f) publish a list of members of the Central, State and District crisis
groups;
g) take measures to create awareness amongst the public with a view

to preventing chemical accidents.
4. Functions of the Central Crisis Group:
1. The Central Crisis Group shall be the apex body to deal with major
chemical accidents and to provide expert guidance for handling major
chemical accidents.
2. Without prejudice to the functions specified under sub-rule (1), the

Central Crisis Group shall,-
a) continuously monitor the post-accident situation arising out of a
major chemical accident and suggest measures for prevention and
to check recurrence of such accidents;
b) conduct post-accident analysis of such major chemical accidents
and evaluate responses;
c) review district off-site emergency plans with a view to examine its
adequacy in accordance with the Manufacture, Storage and Import
of Hazardous Chemicals, Rules and suggest measures to reduce
risks in the Industrial pockets;
26
d) review the progress reports submitted by the State Crisis Groups;
e) respond to queries addressed to it by the State Crisis Groups and
the District Crisis Groups;
f) publish a State-wise list of experts and officials who are concerned

with the handling of chemical accidents;
g) render, in the event of a chemical accident in a State, all financial
and infrastructural help as may be necessary.
5. Constitution of State Crisis Group:
(i) The State Government shall constitute a State Crisis Group for
management of chemical accidents within thirty days from the date
of the commencement of these rules.
(ii) The composition of the State Crisis Group shall be as specified in
Schedule 6.
(iii) The State Crisis Group shall meet at least once in three months and
follow such procedure for transaction of business as it deems fit.
(iv) Notwithstanding anything contained in sub-rule (2), the State Crisis

Group may co-opt any person whose assistance or advice is
considered useful in performing any of its functions, to participate in
the deliberation of any of its meetings.
6. Functions of the State Crisis Group:
1. The State Crisis Group shall be the apex body in the State to deal
with major chemical accidents and to provide expert guidance for
handling major chemical accidents.
State Crisis Group shall,-
a) review all district off-site emergency plans in the State
with a view to examine its adequacy in accordance with
the Manufacture, Storage and Import of Hazardous
Chemicals, Rules and forward a report to the Central
Crisis Group once in three months;
b) assist the State Government in managing chemical

accidents at a site;
27
c) assist the State Government in the planning,
preparedness and mitigation of major chemical accidents
at a site in the State;
d) continuously monitor the post accident situation arising

out of a major chemical accident in the State and forward
a report to the Central Crisis Group;
e) review the progress report submitted by the District Crisis

groups;
f) respond to queries addressed to it by the District Crisis
groups;
g) publish a list of experts and officials in the State who are
concerned with the management of chemical accidents.
7. Constitution of the District and Local Crisis Groups:
1. The State Governments shall cause to be constituted within thirty

days from the date of commencement of these rules,-
a) District Crisis Groups;

b) Local Crisis Groups;
2. The composition of the District Crisis Group and the Local Crisis
Groups shall be as specified in Schedule 7 and Schedule 8
respectively.
3. The District Crisis Group shall meet every forty five days and
send a report to the State Crisis Group;
4. The Local Crisis Group shall meet every month and forward a
copy of the proceedings to the District Crisis Group.
8. Functions of the District Crisis Group:
1. The District Crisis Group shall be the apex body in the district to
deal with major chemical accidents and to provide expert guidance
for handling chemical accidents;
District Crisis Group shall,-
a) assist in the preparation of the district off-site emergency plan;
28
b) review all the on-site emergency plans prepared by the occupier
of Major Accident Hazards installation for the preparation of the
district off-site emergency plan;
c) assist the district administration in the management of chemical

accidents at a site lying within the district;
d) continuously monitor every chemical accident;
e) ensure continuous information flow from the district to the

Centre and State Crisis Group regarding accident situation and
mitigation efforts;
f) forward a report of the chemical accident within fifteen days to

the State Crisis Group;
g) conduct at least one full scale mock-drill of a chemical accident
at a site each year and forward a report of the strength and the
weakness of the plan to the State Crisis Group.
9. Functions of the Local Crisis Group:
1. The Local Crisis Group shall be the body in the industrial pocket to
deal with chemical accidents and coordinate efforts in planning
preparedness and mitigation of a chemical accident;

Local Crisis Group shall,-
a) prepare local emergency plan for the industrial pocket;
b) ensure dovetailing of the local emergency plan with the district

off-site emergency plan;
c) train personnel involved in chemical accident management;
d) educate the population likely to be affected in a chemical

accident about the remedies and existing preparedness in the
area;
e) conduct at least one full scale mock- drill of a chemical accident

at a site every six months and forward a report to the District
Crisis Group;
f) respond to all public inquiries on the subject.
29
10. Powers of the Members of the Central, State and District Crisis
Groups:
The Members of the Central Crisis Group, State Crisis Groups and District
Crisis Groups shall be deemed to be persons empowered by the Central
Government in this behalf under sub-section (1) of section 10 of the
Environment (Protection) Act, 1986.
11. Aid and assistance for the functioning of the District and Local
Crisis Groups:
1. The Major Accident Hazard installations in the industrial pockets in

the district shall aid, assist and facilitate functioning of the District
Crisis Group;
2. The Major Accident Hazard installations in the industrial pockets
shall also aid, assist and facilitate the functioning of the Local Crisis
Group.
12. Information to the public:
1. The Central Crisis Group shall provide information on request

regarding chemical accident prevention, preparedness and
mitigation in the country;
2. The State Crisis Group shall provide information on request

regarding chemical accident prevention, preparedness and
mitigation to the public in the State;
3. The Local Crisis Group shall provide information regarding possible

chemical accident at a site in the industrial pocket and related
information to the public on request;
4. The Local Crisis Group shall assist the Major Accident Hazard
installations in the industrial pocket in taking appropriate steps to
inform persons likely to be affected by a chemical accident.
2.4. The Building and Other Construction Workers (Regulation of

Employment and Conditions of Service) Act, 1996
1. Definitions:
(1) In this Act, unless the context otherwise requires,-

(a) Building or other Construction work" means the construction,
alteration, repairs, maintenance or demolition- of or, in relation to,
30
buildings, streets, roads, railways, tramways, airfields, irrigation,
drainage, embankment and navigation works, flood control works
(including storm water drainage works), generation, transmission and
distribution of power, water works (including channels for distribution
of water), oil and gas installations, electric lines, wireless, radio;
television, telephone, telegraph and overseas communication dams,
canals, reservoirs, watercourses, tunnels, bridges, viaducts,
aquaducts, pipelines, towers, cooling towers, transmission towers and
such other work as may be specified in this behalf by the appropriate
Government, by notification but does not include any building or other
construction work to which the provisions of the Factories Act, 1948,
or the Mines Act, 1952 apply.
(b) “Building Worker” means a person who is employed to do any skilled,

semiskilled or unskilled manual, supervisory , technical or clerical work
for hire or reward, whether the terms of employment be expressed or
implied, in connection with any building or other construction work but
does not include any such person-
(i) who is employed mainly in a managerial or administrative
capacity; or.
(ii) who, being employed in a supervisory capacity, draws wages
exceeding one thousand six hundred rupees per mensem or
exercises, either by the nature of the duties attached to the office
or by reason of the powers vested in him, functions mainly of a
managerial nature;
(c) "Chief Inspector' means the Chief Inspector of Inspection of Building

and Construction appointed under sub-section (2) of section 42;
(d) "Contractor" means a person who undertakes to produce a given
result for any establishment, other than a mere supply of goods or
articles of manufacture, by the employment of building workers or who
supplies building workers for any work of the establishment; and
includes a sub-contractor;
(e) Director-General" means the Director-General of Inspection appointed
under sub-section (1) of section 42;
(f) “Employer", in relation to an establishment, means the owner

thereof, and includes,-
31
(i) in relation to a building or other construction work carried on by
or under the authority of any department of the Government,
directly without any contractor, the authority specified in this
behalf, or where no authority is specified, the head of the
department;
(ii) in relation to a building or other construction work carried on by
or on behalf of a local authority or other establishment, directly
without any contractor, the chief executive officer of that authority
or establishment;
(iii) in relation to a building or other construction work carried on by

or though a contractor, or by the employment of building workers
supplied by a contractor, the contractor;
(g) “Establishment” means any establishment belonging to, or under the

control of, Government, anybody corporate or firm, an individual or
association or other body of individuals which or who employs building
workers in any building or other construction work; and includes an
establishment belonging to a contractor, but does not include an
individual who employs such workers in any building or construction
work in relation to his own residence the total cost of such construction
not being more than rupees ten lakhs.
2. Registration of establishments:
(1) Every employer shall,-

(a) in relation to an establishment to which this Act applies on its
commencement, within a period of sixty days from such
commencement; and
(b) in relation to any other establishment to which this Act may be
applicable at any time after such commencement, within a period
of sixty days from the date on which this Act becomes applicable
to such establishment, make an application to the registering
officer for the registration of such establishment:
Provided that the registering officer may entertain any such application
after the expiry of the periods aforesaid, if he is satisfied that the
applicant was prevented by sufficient cause from making the
application within such period.
32
(2) Every application under sub-section (1) shall be in such form and shall
contain such particular and shall be accompanied by such fees as
may be prescribed.
(3) After the receipt of an application under sub-section (1), the registering
officer shall register the establishment and issue a certificate of
registration to the employer thereof in such form and within such time
and subject to such conditions as may be prescribed.
(4) Where, after the registration of an establishment under this section,
any change occurs in the ownership or management or other
prescribed particulars in respect of such establishment, the particulars
regarding such change shall be intimated by the employer to the
registering officer within thirty days of such change in such form as
may be prescribed.
3. Registration of building workers as beneficiaries:
(1) Every building worker who has completed eighteen years of age, but
has not completed sixty years of age, and who has been engaged in
any building or other construction work for not less than ninety days
during the preceding twelve months shall be eligible for registration as
a beneficiary under this Act.
(2) An application for registration shall be made in such form, as may be
prescribed, to the officer authorised by the Board in this behalf.
(3) Every application under sub-section (2) shall be accompanied by such

documents together With such fee not exceeding fifty rupees as may
be prescribed.
(4) If the officer authorised by the Board under sub-section (2) is satisfied
that the applicant has complied with the provisions of this Act and the
rules made thereunder, he shall register the name of the building
worker as a beneficiary under this Act:
Provided that an application for registration shall not be rejected
without giving the applicant an opportunity of being heard.
(5) Any person aggrieved by the decision under sub-section (4) may,
within thirty days from the date of such decision, prefer an appeal to
the Secretary of the Board or any other officer specified by the Board
in this behalf and the decision of tile Secretary or such other officer on
such appeal shall be final:
33
Provided that the Secretary or any other officer specified by the Board
in this behalf may entertain the appeal after the expiry of the said
period of thirty days if he is satisfied that the building worker was
prevented by sufficient cause from filing the appeal in time.
(6) The Secretary of the Board shall cause to maintain such registers as
may be prescribed.
4. Identity cards:
(1) The Board shall give to every beneficiary an identity card with his
photograph duly affixed thereon and with enough space for entering the
details of the building or other construction work done by him.
(2) Every employer shall enter in the identity card the details of the building
or other construction work done by the beneficiary and authenticate the
same and return it to the beneficiary.
(3) A beneficiary who has been issued an identity card under this Act shall
produce the same whenever demanded by any officer of Government
or the Board, any inspector or any other authority for inspection.
5. Contribution of building workers:
A building worker who has been registered as a beneficiary under this Act
shall, until he attains the age of sixty years, contribute to the Fund at such
rate per mensem, as may be specified by the State Government, by
notification in the Official Gazette and different rates of contribution may be
specified for different classes of building workers:
Provided that the Board may, if satisfied that a beneficiary is unable to pay
his contribution due to any financial hardship, waive the payment of
contribution for a period not exceeding three months at a time.
6. Effect of non-payment of contribution:
When a beneficiary has not paid his contribution under sub-section (1) of
section 16 for a continuous period of not less than one year, he shall cease
to be a beneficiary:
Provided that if the Secretary of the Board is satisfied that the non-payment
of contribution was for a reasonable ground and that the building worker is
willing to deposit the arrears, he may allow the building worker to deposit
the contribution in arrears and on such deposit being made, the registration
of building worker shall stand restored.
34
7. Fixing hours for normal working day, etc.:
(1) The appropriate Government may, by rules.-

(a) fix the number of hours of work which shall constitute normal
working day for a building worker, inclusive of one or more
specified intervals;
(b) provide for a day of rest in every period of seven days which shall
be allowed to all building workers and for the payment of
remuneration in respect of such days of rest;
(c) provide for payment of work on a day of rest at a rate not less than
the overtime rate specified in section 29.
(2) The provisions of sub-section (1) shall, in relation to the following
classes of building workers, apply only to such extent, and subject to
such conditions, as may be prescribed, namely:-
(a) persons engaged on urgent work, or in any emergency which
could not have been foreseen or prevented;
(b) persons engaged in a work in the nature of preparatory or

complementary work which must necessarily be carried on
outside the normal hours of work laid down in the rules;
(c) persons engaged in any work which for technical reasons has to
be completed before the day is over:
(d) persons engaged in a work which could not be carried on except
at times dependent on the irregular action of natural forces.
8. Wages for overtime work:
(1) Where any building worker is required to work on any day in excess of
the number of hours constituting a normal working day he shall be
entitled to wages at the rate of twice his ordinary rate of wages.
(2) For the purposes of this section, "ordinary rates of wages" means the
basic wages plus such allowances as tile worker is for the time being
entitled to but does not include any bonus
9. Maintenance of registers and records:
(1) Every employer shall maintain such registers and records giving such
particulars of building workers employed by him, the work performed
by them, the number of hours of work which shall constitute a normal
35
working day for them, in day of rest in every period of seven days
which shall be allowed to them, tile wages paid to them, the receipts
given by them and such other particulars in such form as may be
prescribed.
(2) Every employer shall keep exhibited, in such manner as may be
prescribed, in tile place where such workers may be employed,
notices in the prescribed form containing the prescribed particulars.
(3) The appropriate Government may, by rules, provide for tile issue of
wage books or wage slips to building workers employed in an
establishment and prescribe tile manner in which entries shall be
made and authenticated in such wage books or wage slips by the
employer or his agent.
10. Prohibition of employment of certain persons in certain building or
other construction work:
No person about whom the employer knows or has reason to believe that
he is a deaf or he has a defective vision or he has a tendency to giddiness
shall be required or allowed to work in any such operation of building or
other construction work which is likely to involve a risk of any accident either
to the building worker himself or to any other person.
11. Drinking water:
(1) The employer shall make in every place where building or other
construction work is in progress, effective arrangements to provide and
maintain at suitable points conveniently situated for all persons
employed there in, a sufficient supply of wholesome drinking water.
(2) All Such points shall be legible marked “Drinking Water” in a language
understood by a majority of the person employed in such place and no
such point shall be situated within six metres of any washing place,
Urinal or latrine.
12. Latrines and urinals:
In every place where building or other construction work is carried on, the
employer shall provide sufficient latrine and urinal accommodation of such
types as may be prescribed and they shall be so conveniently situated as
may be accessible to the building workers at all times while they are in such
place:
36
Provided that it shall not be necessary to provide separate urinals in
any place where less than fifty persons are employed or where the
latrines are connected to a water-borne sewage system.
13. Accommodation:
(1) The employer shall provide, free of charges and within the work site or
as near to it as may be possible temporary living accommodation to all
building workers employed by him for such period as the building or
other construction work is in progress.
(2) The temporary accommodation provided under sub-section (1) shall
have separate cooking place bathing, washing and lavatory facilities
(3) As soon as may be, after the building or other construction work is over,
the employer shall, at his own cost, cause removal or demolition of the
temporary structures erected by him for the purpose of providing living
accommodation cooking place or other facilities to the building workers
as required under sub-section (1), and restore the ground in good level
and clean condition.
(4) In case an employer is given, any land by a Municipal Board or, any
other local authority for the purposes of providing temporary,
accommodation for the building workers under this section, he shall as
soon as may be, after the construction work is over, return the
possession of such land in the same condition in which he received the
same.
14. Crèches:
(1) In every place where in more them fifty female building workers are
ordinarily employed, there shall be provided and maintained, a suitable
room or rooms for the use of children under the, age of six years of
such female workers.
(2) Such rooms shall-

(a) provide adequate accommodation:
(b) be adequately lighted and ventilated;
(c) be maintained in a clean and sanitary condition;

(d) be under the charge of women trained in the care of children and
infants.
37
15. First-aid- Every employer shall provide in all the places where building
or other construction work is carried on such first-aid facilities as may be
prescribed.
16. Canteens, etc.-The appropriate Government may, by rules require the
employer-
(a) to provide and maintain in every place wherein not less than two
hundred and fifty building workers are ordinarily employed, a
canteen for the use of the workers;
(b) to provide such other welfare measures for the benefit of building
workers as may be prescribed.
17. Safety Committee and Safety Officers:
(1) In every establishment wherein five hundred or more building workers

are ordinarily employed, the employer shall constitute a Safety
Committee consisting of such number of representatives of the
employer and the building workers as may be prescribed by the State
Government:
Provided that the number of persons representing the workers, shall, in
no case, be less than the persons representing the employer.
(2) In every establishment referred to in sub-section (1), the employer shall

also appoint a safety officer who shall possess such qualifications and
perform such duties as may be prescribed.
18. Notice of certain accidents:
(1) Where in any establishment an accident occurs which causes death or

which causes any bodily injury by reason of which the person injured is
prevented from working for a period of forty-eight hours or more
immediately following the accident, or which is of such a nature as may
be prescribed, the employer shall give notice thereof to such authority,
in such form and within such time as may be prescribed.
(2) On receipt of a notice under sub-section (1) the authority referred to in
that sub-section may make such investigation or inquiry as it considers
necessary.
(3) Where a notice given under sub-section (1) relates to an accident
causing death of five or more persons, the authority shall make an
inquiry into such accident within one month of the receipt of the notice.
38
19. Framing of model rules for safety measures- The Central
Government may, after considering the recommendation of the expert
committee constituted under section 5, frame model rules in respect of
all or any of the matters specified in section 40 and where any such
model rules have been framed in respect of (my such matter, the
appropriate Government shall while making any rules in respect of that
matter under section 40, so far as is practicable, conform to such model
rules.
20. Powers of Inspectors:
(1) Subject to any rules made in this behalf, an Inspector may, within the
local limits for which he is appointed,-
(a) enter, at all reasonable hours, with such assistants (if any) being
persons in the service of the Government or any local or other
public authority as he thinks fit, any premises or place where
building or other construction work is carried on, for the purpose of
examining any register or record or notices required to be kept or
exhibited by or under this Act, and require the production thereof
for inspection;
(b) examine any person whom he finds in any such premises or place
and who, he has reasonable cause to believe, is a building worker
employed therein;
(c) require any person giving out building or other construction work to
any building worker, to give any information, which is in his power
to give with respect to the names and addresses of the persons to,
for and whom the building or other construction work is given out
or received, and with respect to the payments to be made for tile
building or other construction work;
(d) seize or take copies of such register, record of wages or notices or

portions thereof as he may consider relevant in respect of an
offence under this Act which he has reason to believe has been
committed by the employer; and
(e) exercise such other powers as may be prescribed.
(2) For the purposes of this section, the Director-General or the Chief
Inspector, as the case may be, may employ experts or agencies
39
having such qualifications and experience and on such terms and
conditions as may be prescribed.
(3) Any person required to produce any document or to give any
information required by an Inspector under sub-section (1) shall be
deemed to be legally bound to do so within the meaning of section 175
and section 176 of the Indian Penal Code (45 of 1860).
(4) The provisions of the Code of Criminal Procedure, 1973 (2 of 1974),

shall, so far as may be, apply to such search or seizure under sub-
section (1) as they apply to any search or seizure made under the
authority of a warrant issued under section 94 of the said Code
21. Responsibility of employers:
An employer shall be responsible for providing constant and adequate

supervision of any building or other construction work in his establishment
as to ensure compliance with the provisions of this Act relating to safety and
for taking all practical steps necessary to prevent accidents.
22. Responsibility for payment of wages and compensation:
(1) An employer shall be responsible for payment of wages to each building

worker employed by him and such wages shall be paid on or before
such date as may be prescribed.
(2) In case the contractor fails to make payment of compensation in
respect of a building worker employed by him, where he is liable to
make such payment when due, or makes short payment thereof, then,
in the case of death or disablement of the building worker, the employer
shall be liable to make payment of that compensation in full or the
unpaid balance due in accordance with the provisions of the
Workmen's Compensation Act, 1923 (8 of 1923), and recover the
amount so paid from the contractor either by deduction from any
amount payable to the contractor under any contract or as a debt
payable by the contractor.
23. Notice of commencement of building or other construction work:
(1) An employer shall, at least thirty days before the commencement of any
building or other construction work, send or cause to be sent to the
Inspector having jurisdiction in the area where the proposed building or
other construction work is to be executed, a written notice containing-
40
(a) the name and situation of the place where the building or other
construction work is proposed to be carried on;
(b) the name and address of the person who is undertaking the
building or other construction work:
(c) the address to which communications relating to the building or
other construction work may be sent;
(d) the nature of the work involved and the facilities, including any
plant and machinery, provided;
(e) the arrangements for the storage of explosives, if any, to be used
in the building or other construction work;
(f) the number of workers likely to be employed during the
various stages of building or other construction work;
(g) the name and designation of the person who will be in overall
charge of the building or other construction work at the site;
(h) the approximate duration of the work;
(i) such other matters as may be prescribed.

(2) Where any change occurs in any of the particulars furnished under
sub-section (1), the employer shall intimate the change to the
Inspector within two days of such change.
(3) Nothing contained in sub-section (1) shall apply in case of such class
of building or other construction work as the appropriate Government
may by notification specify to be emergent works.
24. Penalty for contravention of provisions regarding safety measures:
(1) Whoever contravenes the provisions of any rules made under section
40 shall be punishable with imprisonment for a term which may extend
to three months, or with fine which may extend to two thousand rupees,
or with both, and in the case of a continuing contravention, with an
additional fine which may extend to one hundred rupees for every day
during which such contravention continues after conviction for the first
such contravention.
(2) If any person who has been convicted of any offence punishable under
sub-section (1) is again guilty of an offence involving a contravention or
failure of compliance of the same provision, he shall be punishable on
41
a subsequent conviction with imprisonment for a term which may
extend to six months or with fine which shall not be less than five
hundred rupees but which may extend to two thousand rupees or with
both:
Provided that for the purposes of this sub-section, no cognizance shall be
taken of any conviction made more than two years before the commission
of the offence for which the person is subsequently being convicted:
Provided further that the authority imposing the penalty, if it is satisfied that
there are exceptional circumstances warranting such a course may, after
recording its reasons in writing, impose a fine of less than five hundred
rupees.
25. Penalty for failure to give notice of the commencement of the
building or other construction work:
Where an employer fails to give notice of tile commencement of the building

or other construction work under section 46, he shall be punishable with
imprisonment for a term which may extend to three months, or With fine
which may extend to two thousand rupees, or with both.
26. Penalty for obstructions:
(1) Whoever obstructs an Inspector in the discharge of his duties under this
Act or refuses or wilfully neglects to afford the Inspector any reasonable
facility for making any inspection, examination, inquiry or investigation
authorised by or under this Act in relation to an establishment shall be
punishable with imprisonment for a term which may extend to three
months, or with fine which may extend to one thousand rupees, or with
both.
(2) Whoever wilfully refuses to produce on the demand of an Inspector any
register or other document kept in pursuance of this Act or prevents or
attempts to prevent or does anything which he has reason to believe is
likely to prevent any person from appearing before, or being examined
by an Inspector acting in pursuance of his duties under this Act shall be
punishable with imprisonment for a term which may extend to three
months, or with fine which may extend to one thousand rupees, or with
both.
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27. Penalty for other offences:
(1) Whoever contravenes any other provision of this Act or any rules made
thereunder or who fails to comply with any provision of this Act or any
rules made thereunder shall, where no express penalty is elsewhere
provided for such contravention or failure, be punishable with fine which
may extend to one thousand rupees for every such contravention or
failure, as the case may be, and in the case of a continuing
contravention or failure, as the case may be. with an additional fine
which may extend to one hundred rupees for every day during which
such contravention or failure continues after the conviction for the first
such contravention or failure.
(2) A penalty under sub-section (1) may be imposed-
(a) by the Director-General where the contravention or failure relates

to a matter to which the appropriate Government is the Central
Government; and
(b) by the Chief Inspector where the contravention or failure relates to

a matter to which the appropriate Government is the State
Government.
(3) No penalty shall be imposed unless the person concerned is given a

notice in writing-
a) informing him of the grounds on which it is proposed to impose a
penalty and
b) giving him a reasonable opportunity of making a representation in
writing within such reasonable time as may be specified in the
notice against the imposition of penalty mentioned therein, and, if
he so desires, of being heard in the matter.
(4) Without prejudice to any other provision contained in this Act, the
Director-General and the Chief Inspector shall have all the powers of a
civil court under the code of Civil Procedure, 1908 (5 of 1908), while
exercising any powers under this section, in respect of the following
matters, namely:-
(a) summoning and enforcing the attendance of witnesses;
(b) requiring the discovery and production of any document;
43
(c) requisitioning any public record or copy thereof from any court or
office;
(d) receiving evidence on affidavits; and
(e) issuing commissions for the examination of witnesses or

documents.
(5) Nothing contained in this section shall be construed to prevent the
person concerned from being prosecuted under any other provision of
this Act or any other law for any offence made punishable by this Act or
by that other law, as the case may be, or for being liable under this Act
or any such law to any other or higher penalty or punishment than is
provided for such offence by this section:
Provided that no person shall be punished twice for the same offence.
Check Your Progress
Fill in the Blanks:
1. EHS is an acronym that stands for _______________________.
2. An act to consolidate and amend the law relating the import, transport,
storage, production, refining and blending of petroleum is
_______________.
3. The _______________ shall be the apex body in the State to deal with
major chemical accidents and to provide expert guidance for handling major
chemical accidents.
Let Us Sum Up
In this Unit you have learnt about the Introduction, List of laws and
regulations relating to Safety and Health of Industrial workers, The
Chemical Accidents (Emergency Planning, Preparedness and Response)
Rules, 1996, The Building and other Construction workers (Regulation of
employment and conditions of service) Act, 1996.
44
1. Environment (E), health (H) and safety (S)

2. Petroleum Act 1934
3. State Crisis Group
45
Unit-3
Fire and Electrical Safety
Structure
Overview
Objectives
3.1. The Fire Triangle
3.2. Classification of Fuels

3.3. Air-Pressurized Water Extinguishers
3.4. Carbon Dioxide Extinguishers
3.5. Dry Chemical Extinguishers

3.6. Rules for Fighting Fires
3.7. How to Use a Fire Extinguisher
3.8. Fire Alarms

3.9. Fire Hazard Analyses and Fire Risk Assessments
3.10. Electrical Safety
Check Your Progress

Let Us Sum Up
Overview
In this Unit you will learn about the Fire Triangle, Classification of Fuels, Air-
Pressurized Water Extinguishers, Carbon Dioxide Extinguishers, Dry
Chemical Extinguishers, Rules for Fighting Fires, How to Use a Fire
Assessments and Electrical Safety.
Objectives

 Fire Triangle and Classification of Fuels
46
 Air-Pressurized Water Extinguishers, Carbon Dioxide Extinguishers,
Dry Chemical Extinguishers
 Rules for Fighting Fires
 How to Use a Fire Extinguisher

 Fire Alarms and its types
 Fire Hazard Analyses and Fire Risk Assessments
 Electrical Safety
3.1. The Fire Triangle
In order to understand how fire extinguishers work, you first need to know a
little bit about fire. Four things must be present at the same time in order to
produce fire:
 Enough oxygen to sustain combustion,
 Enough heat to raise the material to its ignition temperature,

 Some sort of fuel or combustible material, and
 The chemical, exothermic reaction that is fire.
Take a look at the following diagram, called the "Fire Triangle"
Oxygen, heat, and fuel are frequently referred to as the "fire triangle." Add in
the fourth element, the chemical reaction, and you actually have a fire
"tetrahedron." The important thing to remember is: take any of these four
things away, and you will not have a fire or the fire will be extinguished.
Essentially, fire extinguishers put out fire by taking away one or more
elements of the fire triangle/tetrahedron.
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Fire safety, at its most basic, is based upon the principle of keeping fuel
sources and ignition sources separate.
3.2. Classification of Fuels
Not all fuels are the same, and if you use the wrong type of fire extinguisher
on the wrong type of fuel, you can, in fact, make matters worse. It is
therefore very important to understand the four different classifications of
fuel.
 Class A - Wood, paper, cloth, trash, plastics Solid combustible
materials that are not metals.
 Class B - Flammable liquids: gasoline, oil, grease, acetone Any non-

metal in a liquid state, on fire.
 Class C - Electrical: energized electrical equipment As long as it's
"plugged in," it would be considered a class C fire.
 Class D - Metals: potassium, sodium, aluminum, magnesium
Unless you work in a laboratory or in an industry that uses these materials,
it is unlikely you'll have to deal with a Class D fire. It takes special
extinguishing agents (Metal-X, foam) to fight such a fire.
Classification Materials Suitable portable

applications
1 2 3
CLASS A Fires in ordinary combustible Fire appliances expelling

materials such as wood, water, (Soda-Acid fire
paper, textiles etc. Where the extinguishers or water gas
cooling effect with water is type fire extinguishers
essential for the extinction of
fire.
Fire extinguishers
Fires in flammable liquids like
CLASS 'B' discharging foam, carbon
oils, solvents, petroleum
dioxide or dry chemical
products, varnishes, paints
powder.
etc. where blanketing effect is
essential
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CLASS 'C' Fires involving gaseous Fire extinguishers
substance under pressure discharging dry chemical
where it is necessary to dilute powder or carbon dioxide.
the burning gas at a very fast
rate with an inert gas or
powder.
Fire involving metals like

CLASS 'D'
magnesium, aluminium etc. Fire extinguishers
where burning metal is discharging special dry
reactive to water and which chemical powder.
require special extinguishing
media or techniques.
Electric Fire
Fires involving electric
equipment where the electrical Fire extinguishers
non-conductivity of the discharging chlorine
extinguishing media is of bromomethane, carbon
prime importance. dioxide.
Most fire extinguishers will have a pictograph label telling you which fuels
the extinguisher is designed to fight. For example, a simple water
extinguisher might have a label like the one shown below, indicating that it
should only be used on Class A fuels.
3.3. Air-Pressurized Water Extinguishers
APW Extinguisher:
APW stands for "air-pressurized water." APWs are large, silver

extinguishers which are filled about two-thirds of the way with ordinary tap
water, then pressurized with normal air. In essence, an APW is just a giant
squirt gun.
APWs stand about 2 feet tall and weigh approximately 25 pounds when full.
They are designed for Class A (wood, paper, cloth) fires only.
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Points to remember about water extinguishers:
1. Never use water to extinguish flammable liquid fires. Water is

extremely ineffective at extinguishing this type of fire, and you may,
in fact, spread the fire if you try to use water on it.
2. Never use water to extinguish an electrical fire. Water is a good
conductor, and there is some concern for electrocution if you were to
use water to extinguish an electrical fire. Electrical equipment,
including computers, must be unplugged and/or de-energized before
using a water extinguisher on it.
3. APWs extinguish fire by taking away the "heat" element of the fire
triangle.
3.4. Carbon Dioxide Extinguishers
Carbon Dioxide extinguishers are filled with non-flammable carbon dioxide

gas under extreme pressure. You can recognize a CO2 extinguisher by its
hard horn and lack of pressure gauge. The pressure in the cylinder is so
great that when you use one of these extinguishers, bits of dry ice may
shoot out the horn.
CO2 cylinders are red and range in size from 5 lbs to 100 lbs or larger. In
the larger sizes, the hard horn will be located on the end of a long, flexible
hose.
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Extinguisher Label CO2s are designed for Class B and C (flammable liquid
and electrical) fires only.
Carbon dioxide extinguishes work by displacing oxygen, or taking away the
oxygen element of the fire triangle. The carbon dioxide is also very cold as it
comes out of the extinguisher, so it cools the fuel as well.
 CO2s may be ineffective at extinguishing Class A fires because they
may not be able to displace enough oxygen to successfully put the
fire out. Class A materials may also smolder and re-ignite.
 CO2s will frequently be found in laboratories, mechanical rooms,
kitchens, and flammable liquid storage areas.
 All CO2 extinguishers at USC undergo hydrostatic testing and
recharge every five years.
3.5. Dry Chemical Extinguishers
Dry Chemical Extinguishers come in a variety of types. You may see them
labeled:
"DC", short for "dry chem"

"ABC" indicating that they are designed to extinguish class A, B and C
fires, or
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"BC" indicating that they are designed to extinguish class B and C fires.
ABC fire extinguishers are filled with a fine yellow powder. The greatest
portion of this powder is composed of monoammonium phosphate. Nitrogen
is used to pressurize the extinguishers.
ABC extinguishers are red and range in size from 5 lbs to 20 lbs on
campus.
ABC Extinguisher DC Extinguisher
BC Extinguisher
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It is extremely important to identify which types of dry chemical
extinguishers are located in your area. Read the labels and know their
locations! You don't want to mistakenly use a "BC" extinguisher on a Class
A fire, thinking that it was an "ABC" extinguisher.
Extinguisher Label: An "ABC" extinguisher will have a label like this,

indicating that it may be used on class A,B, and C fires.
Dry chemical extinguishers put out fire by coating the fuel with a thin layer of
dust, separating the fuel from the oxygen in the air. The powder also works
to interrupt the chemical reaction of fire, so these extinguishers are
extremely effective at putting out fire.
These extinguishers will be found in a variety of locations. New buildings will

have them located in public hallways. They may also be found in
laboratories, mechanical rooms, break rooms, chemical storage areas,
offices, university vehicles, etc.
Dry chemical extinguishers with powder designed for Class B and C fires
may be located in places such as commercial kitchens or areas with
flammable liquids.
3.6. Rules for Fighting Fires
Fires can be very dangerous and you should always be certain that you will
not endanger yourself or others when attempting to put out a fire. For this
reason, when a fire is discovered:
SOUND THE ALARM: If you discover or suspect a fire, sound the building
fire alarm. If there is no alarm in the building, warn the other occupants by
knocking on doors and shouting as you leave.
LEAVE THE BUILDING: Try to rescue others only if you can do so safely.
Move away from the building and out of the way of the fire department.
Don't go back into the building until the fire department says it is safe to do
so.
CALL THE FIRE DEPARTMENT: Give as much information as possible to

the emergency dispatcher.
Total and immediate evacuation is safest. Only use a fire extinguisher if the
fire is very small and you know how to do it safely. If you can't put out the
53
fire, leave immediately. Make sure the fire department is called -- even if
you think the fire is out. However, before deciding to fight the fire, keep
these rules in mind:
Never fight a fire if:
 You don't know what is burning. If you don't know what is burning,
you don't know what type of extinguisher to use. Even if you have an
ABC extinguisher, there may be something in the fire which is going
to explode or produce highly toxic smoke. Chances are, you will
know what's burning, or at least have a pretty good idea, but if you
don't, let the fire department handle it.
 The fire is spreading rapidly beyond the spot where it started. The
time to use an extinguisher is in the incipient, or beginning, stages of
a fire. If the fire is already spreading quickly, it is best to simple
evacuate the building, closing doors and windows behind you as you
leave.
 Your instincts tell you not to. If you are uncomfortable with the
situation for any reason, just let the fire department do their job.
 The final rule is to always position yourself with an exit or means of

escape at your back before you attempt to use an extinguisher to put
out a fire. In case the extinguisher malfunctions, or something
unexpected happens, you need to be able to get out quickly, and
you don't want to become trapped. Just remember, always keep an
exit at your back.
3.7. How to Use a Fire Extinguisher
The simple way to use the fire extinguisher is P.A.S.S.
It's easy to remember how to use a fire extinguisher if you can remember
the acronym PASS, which stands for Pull, Aim, Squeeze, and Sweep.
Pull the Pin
This will allow you to discharge the extinguisher.
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Aim at the Fire
 Aim at the base of the fire.

 If you aim at the flames (which is frequently the temptation), the
extinguishing agent will fly right through and do no good. You want
to hit the fuel.
Squeeze the Handle
 Squeeze the top handle or lever.
 This depresses a button that releases the pressurized extinguishing

agent in the extinguisher.
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Sweep Side to Side
 Sweep from side to side until the fire is completely out.

 Start using the extinguisher from a safe distance away, then move
forward. Once the fire is out, keep an eye on the area in case it re-
ignites.
3.8. Fire Alarms
Whether you are upgrading your fire protection systems in your building or
need to install new fire alarms, it is important to understand the different
types of commercial fire alarms available. From the automatic alarm
systems to the manual alarms, there are quite a few things you should know
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before blindly choosing a system. Let’s take a look at some fire alarm
systems you could choose for your commercial space.
There are two distinct types of fire alarms you can have in your commercial
space. The first is an automatic fire alarm. When these alarms detect heat
or smoke, they send an audio-visual alert throughout the building to alert the
occupants of danger. The next type of fire alarm is a manual alarm. These
fire alarms have pull stations stationed around your building. When a fire is
seen or smelled by one of your employees, they simply pull the leveler and
alert the occupants. Manual alarms come in a variety of designs and colors.
Types of Commercial Fire Alarms:
Just as there are different categories of fire alarms, there are also different
types. Let’s take a look at the types of fire alarms and the features they
offer.
Conventional Fire Alarms: Conventional fire alarms include a number of
different “zones” that are hardwired to your central control panel. These
systems allow you to be able to put separate fire alarms in each section of
your building and helps to monitor if an alarm is broken.
Addressable Fire Alarms: These fire alarms are also called “intelligent
systems” as they monitor the fire alarms in your building. Addressable
alarms allow you to choose between automatic and manual alarms. Each
alarm installed in this system has its own address, which allows you to see
which alarm is working and which are failing. Addressable fire alarms are
more expensive because of the monitoring features.
Hybrid Fire Alarms: Hybrid alarms combine the hardwired zone features of
conventional fire alarms with the addressable loops of the addressable fire
alarms into a single panel. This combined technology fits some of the
settings better than either the addressable or the conventional alarm.
When choosing a new commercial fire alarm, it is important to choose the

alarm that is right for your space.
There are an array of portable fire extinguishers, fire alarms, and sprinkler
systems to keep commercial kitchens safe. There are highest quality alarm
systems to keep your business safe from fires and carbon monoxide
poisoning.
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3.9. Fire Hazard Analyses and Fire Risk Assessments
Fire hazards are a broad category. It includes anything which impedes the
function of fire protection material or equipment, as well as anything that
inhibits fire safe behavior. For instance, an obstruction which impedes safe
evacuation and a malfunctioning sprinkler system would both be considered
fire hazards. This is because a facility's level of risk factors in both the
probability that a fire will occur and the severity of the potential harm that
could be caused by a fire if it did occur.
What counts as a fire hazard has changed over time—in general, societies
around the world have become less tolerant of fire risks, and as such, far
more conditions are seen as being hazardous or unsafe. Taking this into
account, a “fire hazard” can thus be understood as anything which
significantly increases the likelihood of a fire occurring, intensifies a fire’s
spread, or increases the potential harm a fire could cause.
An item may also be considered a hazard in one context but be seen as

non-hazardous in another, lower-risk environment. For example, in
occupational environments that require the use of heat or flame, the use of
non-fire resistant clothing would be considered hazardous. Minor amounts
of flammable materials that would be considered acceptable in normal
58
environments become unacceptable if placed in an environment that has an
ignition source.
Because the amount of hazard (risk) that is created by an individual item is
dependent on the environment which it exists within, fire hazards are
typically analyzed from a “whole-workplace” or “whole-building” perspective.
These risk assessments, which are often legally required, are referred to as
Fire Hazard Analyses (FHA) or Fire Risk Assessments (FRA).
An FHA is a type of engineering analysis that is designed to describe the
risk of fire present in an environment in both qualitative (descriptive) and
quantitative (numeric) terms. The FHA considers the severity of hazards in
the area by evaluating the total risk of hazards in a given area. An FHA can
be risk-based and hazard-based—the former considers the likelihood of a
given scenario occurring, while the hazard-based model is solely concerned
with what could happen, regardless of probability.
The first step of any fire risk assessment is to identify fire hazards. Fire
hazards in your workplace are anything that may create a fire. If you know
the fire triangle, then it will be no surprise that fire hazards come into three
categories:
 Sources of ignition/heat
 Sources of fuel
 Sources of oxygen
These are the 3 things needed for a fire - Ignition, fuel and oxygen.
Why is identifying fire hazards so important that it is the first step in fire risk
assessment? Because once you know the hazards, you can calculate the
risk. And then you can work on ways to reduce the risk and prevent fires
happening.
You might not be able to remove all of the fire hazards in your workplace.
Fire hazards are everywhere, and when you go through the list, you will
probably find that many exist in your work environment. But remember fire
needs all three elements, of fuel, heat and oxygen to survive. Control these
hazards. Keeping them apart. Reduce the risk.
Let's go through the list of some common examples that might tell you there
is a potential fire waiting to happen at work.
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Ignition fire hazards:
The majority of fires need an ignition source to start. Identifying ignition

sources in your workplace is important so that you can remove them, or
control them. Not all ignition sources can be removed. But, where they can't
be removed, they can be separated from combustible materials and other
fuel sources.
 Smoking materials
 Electrical faults
 Overheating machinery
 Radiated heat
 Cooking equipment
 Portable and fixed heaters
 Sparks from equipment

 Overloaded electrical circuits
 Static electricity
 Friction
 Hot surfaces
 Steam pipes
 Electrical equipment
 Boilers
 Welding equipment
 Naked flames
Hot works processes: It's important to consider the use and location of
ignition sources. Electrical equipment might be perfectly safe for everyday
use. But, take it into a flammable atmosphere, and the risk increases
dramatically.
Fuel fire hazards:
Fuel is needed to burn for a fire to start, and to maintain the fire. When we
talk about fuel as a fire hazard, we don't just mean petrol and diesel, the fuel
you fill up your car with. Fire is not fussy and accepts a wide variety of fuel
sources. Fuel for fire can come in the form of combustible materials, oils,
60
flammable liquids and gases. Removing the fuel, reducing fuel, and
separating the fuel from ignition sources are all ways to minimise fire risk.
The type of fuel will usually determine which of the 6 classes of fire is
created, and the type of fire extinguisher that needs to be used to attack it.
So what types of fuel are present in your workplace? Here are some
examples:
 Paper
 Cardboard
 Packaging
 Waste
 Furniture
 Textiles
 Fixures and fittings

 Electrical insulation
 Metals
 Wood
 Plastics
 Foam
 Sealants
 Structural materials
 Wall linings
 Ceiling linings
 Flooring
 Cladding
 Paints
 Inks
 Adhesives
 Cleaning fluids
 Chemicals
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 Liquids
 Solvents
Most furniture, fixtures, fittings are flame-resistant, but not all. It's best to
check to make sure. Finishes can deteriorate over time so look for signs of
wear and tear.
Structural materials are not easily combustible, but some are covered with
layers of cardboard or wallpaper which may spread the fire. There have
been cases recently regarding cladding (e.g. Grenfell) acting as a fuel
source and quickly spreading the fire. So never assume that building
materials are non-combustible.
Flammable chemicals, liquids and solvents need to be stored correctly and
used safely to reduce fire risks. Flammable liquids give off vapours that can
travel, so careful consideration of the distance from ignition sources is
needed.
Oxygen fire hazards:
Oxygen is everywhere. We need it to survive, and luckily for us, it's in the air
we breathe. Fires also need oxygen to survive. Knowing where oxygen is
readily available, and how it can be stopped, can help prevent fire spread.
 Open windows
 Open doors
 Natural ventilation
 Air conditioning systems

 Holes in the structure
 Oxidising materials
 Oxygen cylinders
 Oxygen systems
Not all ventilation is bad. Sometimes, you might need good ventilation to
reduce the risk of fire. For example, when storing or using flammable
liquids, good ventilation can prevent the build-up of vapour and the creation
of a flammable atmosphere.
This list is just an example, and your workplace may have different hazards
present. Identify fire hazards through a simple walk around or inspection,
62
use this list to help you look for fire dangers. Identify items from each source
- ignition, fuel and oxygen. How do they interact with each other? Give
particular attention when ignition sources are close to fuel sources. Could
they create a fire risk?
And don't forget to think about the type of work that is carried out. It's easy
to just look at an empty work area and forget what happens in it. Especially
when an activity might just be carried out once a month, or once a year.
Maintenance or cleaning work. Work carried out by contractors. Before a
new task is carried out, assess if it introduces any new sources of ignition,
fuel or oxygen.
3.10. Electrical Safety
In the revolution of the world industrial uses of electricity have changed a

mechanically operated factory, railway, and many other economic sections
to electrically operated. The use of electricity gave rise to other types of
industrial accidents.
The dangers associated with the use of electricity may be classified as

follows:
i) Injury from direct contact
a) Injury by shock;
b) Injury from internal burns.
ii) Injury without current flow through body
a) Direct burns from electric arcs, spattered molten metal etc;

b) Radiation burns from very heavy arcs;
c) Physical injury from false starting of machine, failure of crane controls,
explosion of switchgear etc;
d) Injury from fire and explosion from electric ignition of flammable
vapours, gases, liquids and solids; and
e) Eye injury from electric arcs (eg. welder's eye-flash).

iii) Injury from current flow induced in or near the human body by
intense electro magnetic fields
a) Injury from elevation of whole body temperature.

b) Local injury such as cataract formation in the eye,
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c) Burns due to metallic objects in close contact with local parts of the
body.
1. Electrical quantities associated with human Injury:
i) Value of current:
For industrial frequencies of supply (50 cycles per sec.) alternative currents
of 15-20 milli amps prevent the victim from releasing his grasp and this is
the threshold of danger. From grasp 50-80 milli amperes up to several
ampers of current flow, the shock is likely to be fatal. Above this, lethal
internal burns may result.
Currents of 1-5 mA; (perception current) unlikely to cause an injury unless

involuntary movement causes the victim to fall from a height. Currents of 6-
15 mA shock may be painful, victim looses muscular control.
At frequencies in the range 30,000 to 100,000 cycles per sec. the danger
becomes progressively less and the safe current which can flow through the
body without injury becomes progressively larger. At somewhat less than
one megacycle per sec. electric shock ceases to occur and the danger of
current flowing is that of superficial and internal burns.
Direct currents of 0.5 amperes to several amperes are likely to be lethal
shock, and above this internal burns may result.
ii) Values of dangerous voltage:
These values depend upon the resistance of the human body, 10 taken in
conjunction with the current values in (i) above. In general for 50 cycle
alternating current limits may be taken as 24 volts for children and 60 volts
for adults. In wet situations the dangerous voltage may be less, and
depends upon circumstances.
iii) Values of resistances of the human body:
The values extend over a great range from several thousands of ohms with
dry hands and low supplied voltage to only several hundred with damp
hands and mains supply voltages (220-240) volts. For safety it is wise to
assume a value of 500 ohms for dry locations and 200 ohms or less for
persons working in wet places.
2. Capacity and Protection of Conductors:
All apparatus and conductors should be of sufficient size and power for the
work they are intended to do.
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All conductors of electricity should be covered with insulating material and
further protected wherever necessary to prevent danger; or they should be
so placed or enclosed as to prevent danger.
Examples:
i) Conductors in conduit;
ii) Conductors in flexible metallic tubing;
iii) Conductors in metal trunking;

iv) Insulated cables like T.R.S., P.V.C., F.R.L.S.,
Overhead trolley wires of cranes should be (i) either protected by creen
guards with suitable opening for taping; or ii) insulated cables wound on
self-winding drums should be used.
Screw cap lampholders in which the screw portion of the holder and the
lamp cap are conductors, should be fitted with suitable agency.
3. Joints and Connections:
Electrical joints and connections should be of proper construction as

regards conductivity, insulation, mechanical strength and protection.
4. Means for Cutting off Pressure:
Efficient and suitably located means should be provided for cutting off
Pressure from every part of a system. They may be:
 Switches;
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 Switch-fuses;
 Isolating links ; or
 Circuit-breakers
Wherever rapid operations are desirable in the interest of safety, switch

fuses or isolating links are not suitable. The switches' and circuit breaker
controls should be located for ready access.
Transformers, convertors, motors and such apparatus should have separate

switches suitably placed for disconnecting power. They should be carefully
marked.
In the case of motors, switches should be placed close to the starters.

Machines driven by motors should have individual stopping and starting
arrangements easily accessible to the operator.
It is desirable to have locking arrangements for the switches or starters of

the motors, other apparatus to prevent accidental starting or switching on
while persons are working on them. The key after locking should be kept
with the person working on the system. Wherever locking cannot be done,
fuses should be removed and kept by him. In addition warning notices
should also be put up like "MAIN LINE"; "DO NOT CLOSE".
Earthing of the conductors is an additional precaution which may be
necessary to ensure that they are riot charged inductively or by capacity or
by any other chance.
Examples:
a) Overhead lines;
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b) Conductors of high or extra high voltage.
Switches, circuit breakers etc. should be marked wherever necessary to
clearly indicate the circuits they control.
5. Restriction on use of Switch on Neutral Earthed Conductor:
A single pole switch should not be placed in the neutral conductor of a

system which is connected to earth (except for special purposes in
generating stations).
If this conductor is bare, even double pole switch should not be placed in
this conductor except for the purpose of breaking connections with
generators and transformers supplying the power. But the connection with
earth should not thereby be broken.
6. Importance of safety equipment in design and use of switches,
switch-fuses, Circuit breakers and isolating lines:
i) Sufficient capacity for making and breaking contacts;

ii) Cover for switch;
iii) Handle spindle should be a close fit in the hole in the cover to prevent
injury from arcs inside;
iv) "ON" and "OFF" position in switches and circuit breakers should be
clearly marked;
v) Ample space between opposite poles of double and multipole air
break switches and circuit-breakers;
vi) Should make and maintain good contact on being operated without
any special skill or manipulation;
vii) Switches and circuit-breakers should be of such construction that they
cannot be left in partial contact, that there is speedy breaking of
contacts when operated to off position. There should also be other
extra means of controlling the arc where necessary;
viii) Handle should be of sufficient size to withstand the effort required to

operate.
7. Overload and short circuit protection:
This is prevented by providing:

i) Fuses;
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ii) Circuit breakers;
iii) Thermal protection.
Protective apparatus should be set at as Iow current value as possible.
Where time relays for over current protection are deliberately introduced as
in the case of motors etc., possible excessive temperature rise in equipment
and conductors should be considered. The number of items collectively
protected should be limited to avoid
i) over fusing to withstand heavy switching currents and
ii) To ensure sub divisions so that inconvenience from operation 6f
protective gear is not caused.
Fuses, relays and circuit breakers should be of sufficient breaking capacity
to operate safely at short circuit currents.
Arcing or scattering of hot metal of fuses may be prevented by the use of

improved fuses of cartridge or other type having special arrangements for
extinction of arc at reduced current values.
Fuse:
The fuse is one of the most important safety devices in every electrical
circuit designed to give way and break the flow of current if the circuit is
overloaded. 1t protects workmen against shock, electrical equipment
against dangerous overloads, and the plant against fire. The fuse also is a
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convenient device for cutting the electrical current out of a line when work
must be done on it.
When a fuse fails it must be replaced by the same type of fuse with same
capacity after inspection. Use of a heavier fuse or by inserting a metal
connector between the two contacts of the fuse may leave the circuit
unprotected, with very serious results.
Remember that failure of proper fuse is a sign that something is wrong with
the circuit. Look for the circuit that caused the fuse to fail. When you remove
a burnt out fuse or remove one to allow you to work on a line always switch
off the supply first. Otherwise, if not practicable make sure that floor under it
is dry, use a wooden platform to stand on and pull the supply end of the
fuse first. Turn your face away to protect against any possible flash.
If you are working on line, remove switch, put a tag on the box to warn
others not to replace the fuse while you are working. On lines carrying 440
volts or more, cut, off the power supply. Each leg of the circuit should be
earthed and checked with a voltmeter that the circuit is not live.
Requirements:
a) No exposed terminals, fixing screw or metal ends in fuse handle;
b) Fuse elements of cartridge type should ha v, holders of ' safe type:

c) Protection to shield hand from any flash
d) Apart from the fuse holder, the contacts should be shrouded or
protected.
Circuit breakers for use where short circuit current exceeds 10,000 amperes
or 150 MV A should not be direct hand operated.
In the case of oil immersed circuit breakers there is the added risk of
explosions and so the rated capacity should never be exceeded.
Air break circuit breakers without arc control devices should be situated at a
suitable height or guarded suitably to avoid injury from arc or other hot
particles to operator. The vacuum circuit breakers/contactors may be used
to avoid the hazards.
8. Earth Fault Protection Protective Earthing:
All non-current carrying metal parts of electrical equipment are to be

earthed.
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Examples:
i. Metal conduits, bus bar steel trunking and cable sheets.

ii. Non-current carrying metal parts of
a) Switch gear, fuse gear and starters:

b) Power machinery such as motors:
c) Light fittings;
d) Other electrical equipment or appliances.

Earth is to connect the general mass of earth in such manner as will ensure
at all, times an immediate discharge of electrical energy without danger and
to allow sufficient current to flow to blow fuses or operate protective devices
and thereby disconnect faulty apparatus.
Good earthing can be achieved by connecting earth continuity conductor to:
i. Sheath and armours of "supply" cable whenever available;

ii. in the case of supply from own transformer, to a heavy section copper
wire running to the neutral point of the transformers; or
iii. Neutral wire where "protective multiple Earthing" is allowed and

adopted.
In the absence of these, connection should be made' to earth electrode or
electrodes having low resistance to earth.
Connection between earth load and the earth electrode should be made
wherever possible above the ground for facilitating inspection. Joints
involving dissimilar metals should be avoided. All joints should be treated
with a conducting point.
In all cases the earth continuity conductors should have SUFFICIENT
current carrying capacity to take the fault current safely till the fuse or the
circuit breaker blows or trips. The total impedance from any point in the
system to the earthing point and through it to the general mass of earth and
then to the neutral point of the supply substation transformer and back to,
the fault point through the line conductor should be as small as possible.
Wherever conduits and sheaths are used as earth continuity conductors
(Without separate earth wire) earth continuity should be ensured at joints
and junctions by suitable connections.
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9. Earth, Insulation and Continuity Tests:
The purpose of earthing is to make effective contact with the "main body of
earth" and it is not realised often that this is not by any means easy. It is
necessary for affording protection that the resistance or the impedance of
the fault current path should be sufficiently low, so that the current which
flows is adequate to operate the protective gear. When a fault occurs the
earthed metal work will be raised to a potential above earth, the value of the
potential being determined by the fault current which is just not sufficient to
blow the fuses and the resistance of the earth connection. Hence, if the
potential is to be kept to a safe value, the earth resistance must below,
except in those cases where special protective devices such as earth
leakage trips are employed wherever higher resistance can be allowed.
Therefore, it is essential to carryout earth tests frequently in all installations
to check the earth resistances. These can be easily carried out with special
type of instruments.
10. Other Precautions:
Working Space and Means of Access: Adequate working space and
means of access free of danger should be. provided for all apparatus which
have to be worked by any person and sufficient lighting should be provided.
Personal Protective Equipment: Portable or permanent insulation stands
or screens, boots, gloves or other suitable means should be used whenever
necessary to prevent danger.
Competency of Personnel: Only authorised and competent persons
should undertake any work where technical knowledge or experience is
required to avoid danger.
11. Electrical Shock Treatment:
i. If the accident occurs indoors switch off the current from the mains
supply.
ii. If this cannot be done immediately. remove victim without directly
contacting his skin.
iii. If the accident occurs outdoors, push the line wire or conductor away
from the victim with a dry. un painted wooden pole or pull it away with
a loop of dry rope or any other non conductive material.
iv. Send for medical help and start artificial respiration immediately.
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v. Continue persistent artificial respiration till the patient revives or till
there are no chances left. There are cases on record where revival
has occurred after even 3 hours of persistent effort.
Check Your Progress
Fill in the Blanks:
1. Add in the fourth element, ________________ to the fire triangle and

you actually have a fire tetrahedron.
2. APWs extinguish fire by taking away the ______________ element of
the fire triangle.
3. ABC fire extinguishers are filled with a fine yellow powder and the
greatest portion of this powder is composed of ________________.
4. The fire extinguishers are used as per the acronym PASS, which
stands for __________________.
5. The ________________ is one of the most important safety devices in
every electrical circuit designed to give way and break the flow of
current if the circuit is overloaded.
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Let Us Sum Up
In this Unit you have learnt about the Fire Triangle, Classification of Fuels,
Air-Pressurized Water Extinguishers, Carbon Dioxide Extinguishers, Dry
Chemical Extinguishers, Rules for Fighting Fires, How to Use a Fire
Assessments and Electrical safety.
1. the chemical reaction

2. heat
3. monoammonium phosphate
4. Pull, Aim, Squeeze, and Sweep
5. fuse
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Unit-4
Material Handling and Safety
Structure
Overview
Objectives
4.1. Workers Safety

4.2. Material Handling
4.3. Manual Material Handling
4.4. Mechanized Material Handling Equipment’s and Accessories

Check Your Progress
Let Us Sum Up
Overview
In this Unit you will learn about the Workers Safety, Material Handling,
Manual Material Handling, Mechanized Material Handling Equipment’s and
Accessories.
Objectives

 Workers Safety
 Material Handling and its types
 Manual Material Handling

 Mechanized Material Handling Equipment’s and Accessories
4.1. Workers Safety
When moving materials, workers are subject to all sorts of potential risks
they may not even think about. They could get sprains from lifting heavy
loads improperly. They get fractures from being struck by objects. They
could get cuts, bruises, or even burns from materials stored improperly.
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As an employer, it’s your job to keep your workers safe. It’s also your job to
ensure that your employees know how to work safely.
OSHA guidelines require you to train your employees in safe workplace
practices. They should know how to operate machinery, how to safely move
materials, and how to handle potentially hazardous materials.
Protect Against Workplace Injuries:
All of this means that OSHA material handling guidelines help protect your
workers against workplace injuries.
OSHA defines ergonomics as the practice of crafting a job to fit the
employee, rather than the other way around. This helps avoid work injuries
and work-related musculoskeletal disorders, such as carpal tunnel
syndrome, tendonitis, rotator cuff injuries, and low back injuries.
It’s especially important in material handling when workers are put through
any number of stresses on any given day. Take heavy lifting, for example. A
number of factors combine to make this a high-risk activity for workers,
including:
 Weight of the object
 Awkward posture
 Inadequate holds
 Improper lifting technique
 High-frequency lifting
 Long-duration lifting
OSHA’s ergonomic guidelines for material handling help minimize the risk of
your employees suffering injuries. Instead of just getting the job done, your
employees will get the job done right so that they can keep showing up to
work.
Protect Your Equipment:
Of course, these guidelines don’t just keep your workers safe. They also
help protect your equipment. Think of it this way. Let’s say your employees
are handling flammable or combustible materials using equipment. And let’s
say they’re handling those materials incorrectly. Lo and behold, a fire
breaks out.
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Now, on top of potential employee injuries, your workplace is damaged, the
equipment used to handle those materials is damaged, and the materials
themselves have to be replaced. In short, you’ve got a first-class mess on
your hands.
Depending on what equipment is damaged and how badly it’s damaged,
you could be staring down an expensive repair bill on top of project delays
and workers compensation payments if a worker was harmed.
Now, picture an alternative version of the story. Instead of creating an
expensive disaster, your employees handled the flammable materials
safely. No workers or equipment were harmed and everyone went home
happy.
4.2. Material Handling
Material handling is the job done by every worker in an industry from

unloading raw materials, dispatching the finished product and Materials
handled between operations in every department or plant of the company.
Mechanized material handling equipment has come into the industry to

eliminate the human handling or to assist the person to handle move, varied
and heavy objects. Mechanical handling of materials reduces manufacturing
cost and increases the productivity. At the same time mechanical handling
has, a new set of hazards and injuries.
The accidents in material handling are almost due to human failure or
unsafe acts rather than mechanical failures or unsafe conditions. The ratio
between unsafe acts and unsafe conditions in material handling accidents is
4 to 1.
The following statistics, highlights the magnitude of material handling

problems to be solved in eliminating the unsafe acts and conditions.
1. For every ton of finished product 50 to 120 ton of equivalent material
has to be handled.
2. 2/3 of manufacturing cycle is material handling.
3. 40% accidents are due to unsafe material handling.
4. 80% accidents in material handling are due to human failure or

unsafe acts.
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Materials are handled in three methods:
The material handling is mostly carried by any one if the three following
methods:
i. Manual handling
ii. Manual Handling with the help of hand tool
iii. Mechanized material handling
The accidents and injuries that are common in unsafe material handling
work are:
a. Dropping or slipping of objects on the foot.
b. Body organs pressed in between objects and lifting tackles.

c. Cuts due to sharp edges.
d. Burns due to hot or corrosive substance.
e. Sprains while lifting materials by wrong method.

f. Scalp injuries while working in confined spaces.
4.3. Manual Material Handling
Manual handling means using physical strength to move materials. This

method increases the possibilities of injuries and ads to the cost of product.
To reduce the number of material handling injuries and increase the
efficiency, material handling to be minimized by combining and eliminating
operations or mechanization. Even after all elimination and mechanization
there will be still objects to be lifted manually for which the following factors
are to be taken into consideration for safe acts in materials handling.
Factors to be considered before attempting to lift a load:
1. Material to be handled, terrain or the surface.
2. The distance to be moved.

3. The direction of the load to be taken.
4. Volume and weight, shape and size.
5. Frequency.
6. Mode of handling.
TEACH: - Training in safe material handling practice.
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WATCH: - Remind constantly for safety.
CATCH: - Correcting unsafe acts.
Training and constant supervision will reduce the unsafe acts:
1. Inspect materials for sleeves, jagged edges burns, rough or slippery

surfaces.
2. Get a firm grip on the object.
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3. Keep fingers away from material resting points, especially when
setting down on the rollers.
4. When handling timber, pipe or other long objects keep hands away
from the ends to prevent them from being pinched.
5. Wipe of greasy, wet, slippery or dirty objects before trying to handle
them.
6. Most strains and back injuries occur while lifting and setting down
objects by hands.
Proper method of manual handling:
a. Consider the size, weight and shape of the object to be carried. Do

not lift more than the object that can be handled comfortably. If
necessary get help from others.
b. Set feet solidly. One foot can be slightly ahead of the other for
increased effectiveness. Feet should be enough apart to give good
balance and stability (approximately the width of the shoulder).
c. Get close to the load as possible. Bend legs about 90 degrees at the
knees. Crouch do not squat. It takes about twice as much effort to get
up from squat
d. Keep the back as straight as possible. Bend at the hips, not the
middle of the back.
e. Grip the object firmly. Maintain the grip while lifting or carrying. Before
changing or adjusting the grip set the object down again.
f. Straighten the legs to lift the object, and at the same time bring the
back to a vertical position. Look upward when beginning to lift.
g. Never carry a load you cannot see over or around. Make sure the path
of travel is clear. Carry the object close to the body.
h. Never turn at the waist, to change the direction or to put an object
down. Turn the whole body and crouch down to lower the object. To
keep hands from being pinched against down first, so that the fingers
can be removed from under the sides.
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Team Lifting and Carrying:
a. When two or more men must carry a single object, they should adjust
the load so that it rides in level and so that each person carries an
equal part of the load. Trial lifts can be made before proceeding.
b. When two men carry long sections of pipe or any lengthy material,
they should not carry on the same shoulder and walk in unison.
Shoulder pads will prevent cutting of shoulders and help to reduce
fatigue.
c. When a gang of men carries a heavy object like a rail, the foreman or
the leader should direct the work and special tools such as tongs
should be used.
d. Normally the gang leader has different signals, like blowing whistle or
hand clapping for different operations of which the men are familiar.
e. New employees and men who move slowly need special attention.
Handling materials of Specific Shapes:
Sheet metal: Sharp edges of sheet metal is to considered and leather hand
gloves and safety boot to be used.
Barrel and Drum: Barrel lifting handle or manila rope to roll up or down on
a ramp to be used.
Glass panes: Hand gloves and long leather sleeves, apron, leg guard and
safety boot to be worn.
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Long objects: Long pieces of pipes, bars, timber should be carried over the
shoulders with the front end raised to prevent striking other employees.
Shoulder pads to protect abrasion on the shoulder to be used.
Scrap metals: The irregularly shaped jagged, mingled objects and strips or
pieces may fly when piece is removed from a pile. Workmen should wear
goggles, leather gloves, safety boot, leg guard and apron.
Gas cylinders: Compressed gas cylinders should be handled carefully. Do
not drag the cylinder on floors.
Boxes, cartons and sacks: The best way to handle boxes and cartons is
to grasp the alternate top and bottom corners.
While handling materials manually the safety equipment should be

appropriate to the type of material. Where toxic or irritating solids are
handled, workmen should take daily showers to remove the materials from
the persons.
4.4. Mechanized Material Handling Equipment’s and Accessories
Mass production would be impossible without the highly mechanized

material handling equipment now in use. Equipment’s for handling material
commonly used in industrial establishments are:
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i) Hand lift trucks
ii) Dragging or sliding on skids or rollers
iii) Wheel barrows
iv) Hand trucks, power trucks and tractors

v) Hoisting apparatus
vi) Conveyors
vii) Overhead travelling cranes

viii) Mechanical shovels
ix) Elevators and escalators
x) Chutes (gravity or under pressure) and

xi) Pipe lines or pumps for liquids
a. Cranes:
EOT or MOBILE cranes - they should not be over loaded. EOT crane is to
be used to lift and move materials and not to be used as side pulling.
Cranes should not be stopped with jerky motion, where the swinging
material will fall due to displacement of slings. Crane movements, while
material is being moved or repair work is being done should be governed by
a standard code of signals transmitted to the crane operator. Clear signals
only to be taken, when the signal is not clear, crane should not be operated.
The operator should move the hoisting apparatus only on signals from the
proper person, but to stop signal should be obeyed regardless of who gives
it, otherwise it would result an accident. The operator should be governed
absolutely by the signal.
Crane rigger should be distinguishable from others, for easy spotting by the
crane operators. Employees who work near cranes or assist in hooking on
or arranging loads should be instructed to keep out from and under load.
Safe acts in operating a crane:
1. No one but an authorized operator be allowed to use any crane.

2. When on duty, authorized operator should remain in the crane cabin
ready for prompt service.
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3. Operator should never go on top of the crane or permit anyone else
to do so without opening the main power disconnect switch and
looking it ‘OFF’ with a padlock
4. Before moving the trolley or crane bridge, operator should be sure

that the hook is high enough to clear obstacles.
5. Operator should never permit the crane to bump into another crane
or the buffers.
6. Operator should Examine the crane at the start of every shift for
loose or defective gears, keys, runway railings, warning bell, signs,
switches, down shop leads and cables and report defects. Make
sure that the crane is kept clear and well lubricated.
7. While hoisting equipment is in operation, the operator should not be
permitted to perform any other work and he should not leave his
position at the controls until the load has been safely landed or
returned to ground.
8. Operator should not carry the load over men on the floor, sound the
bell when necessary.
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9. Operator should not allow men to ride on a load or on crane hooks.
10. If the power goes off, move the controller to ‘OFF’ position until
power is available again.
11. Fire extinguisher should be kept filled and in working condition.

Safety rules for crane operators:
1. Never pick up a load which is beyond the rated load capacity of the
crane.
2. Never move the load or the crane unless you understand the signal.
3. Do not allow the load to swing.
4. When hoisting or lowering the load have clear space between load
and adjacent machineries or objects.
5. Do not smoke while operating a crane. 6. Never leave a load
suspended.
Safety rules for slingers:
1. Check the slings before taking it for use at the beginning of each
shift.
2. A sling that has a stretched leg should not be used.
3. Choose the proper sling (SWL, wire or chain) according to the
weight of the object to be lifted.
4. Use proper attachments so that, when lifted the object will not fall or
tilt.
5. Satisfy yourself before giving orders to crane operator that all slings
are securely holding.
6. Distribute the load equally on the legs of the sling
7. The slings are not kinked, twisted or knotted.

8. Cylinders should be carried in a special cradle.
9. The hook should be centered on the load before hoisting signal
given.
10. Slings should be lying on the center of the crane hook.
11. Hands should be kept out of pinch points, while hooking or
unhooking.
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12. Before slinging a load, find out if the unloading position is clear.
13. Sharp edged objects usually lifted with chain slings. When suitable
chain slings are not available, wire rope sling with proper packing to
protect the wire rope to be used.
14. Loose articles, should not be left on the load while moving the load.
15. When using shackle the pin should be fully screwed.
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16. Machined objects should be lifted with manila rope slings. When
using wire rope slings give wooden packing between the load and
the sling.
17. Never carry load over men.

18. Always guide the load in moving. Go before long objects. When the
load has to be raised and moved due to obstruction tie a line to the
load and guide it.
19. Do not attempt to lift the load when the load is away from vertical
reach of the crane hook.
(b) Fork Lift:
The operation of forklifts differs basically as below from that of an

automobiles.
(a) They are generally steered by rear wheels.

(b) They are easy to control when unloaded.
(c) They are often driven in reverse direction.
(d) They are often steered by one hand and the other hand is used to
operate the controls.
The fork lift truck makes the lift by means of a two or three prong fork
instead of a platform and lifts the load up from the floor permitting high piling
to conserve space. They could also be fitted with special attachments for
handling barrels, paper reels etc.
Safety precautions:
Safety precautions to be observed in operation of fork lift trucks are:

1. Lift trucks require safe guarding for the operator's protection and for
the safety of the other workers. Equally important is the
establishment of the safe practices for the maintenance and
inspection of trucks.
2. Safe operation of lift trucks results in more efficient and profitable

handling of material and reduces losses due to injuries, property
damage, and excessive maintenance.
Hazards:
1. The two primary hazards inherent in the operation of lift trucks are
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a) Collision or overturning of the truck.
b) Movement or collapse of bridge plates or other trucks.
2. Additional danger exists during the handling of materials, bags,
cartons or other articles that may fall from lift. These dangers will
cause severe injuries to the truck operators and passerby as well as
financial loss due to damage. Another serious personal hazard may
exist if lift trucks without overhead protection are operated in close
proximity to low hanging overhead obstructions.
3. Economic losses from accidents include damage to trucks, stock,
finished products, and company facilities. Even "near-misses" and
minor accidents increase truck maintenance costs and reduce
general efficiency.
4. There is every possibility for accident while changing and charging

storage batteries. By wearing chemical goggles, rubber gloves,
aprons, and rubber boots, one can be protected against acid burns
during refilling or handling operations. Rubber mats or clean wooden
floor boards will help to prevent slips and falls and will protect
against electric shock from the charging equipment.
5. Battery changing and charging operations should be performed by

trained and authorized persons.
6. Battery changing and charging operations should be located in
areas designated for that purpose. Facilities should be provided for
flushing and neutralizing spilled electrolyte, for fire protection, for
protecting charging apparatus against damage by trucks, and for
adequate ventilation to dispense gases and fumes from batteries.
7. When filling batteries with electrolyte, acid should be poured, into
water, never the reverse. If electrolyte or concentrated acid is spilled
on skin or clothing, it should be washed immediately with plenty of
water. Eye protection should be worn.
8. Trucks "should, be properly positioned and the brake applied before
attempting to change or charge batteries. When charging batteries
the vent caps should be kept in place to avoid electrolyte spray, the
battery covers should be kept open to dissipate the heat.
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9. Sulphuric acid used should not be allowed to run into the parts of
cast iron, steel etc.
10. Battery terminals should be clean, tight connection and the battery
securely locked in place in the truck. Tools or metal parts should
never be laid on a battery.
11. Smoking/open flame should be prohibited in the charging area.
Health Hazard:
1. Truck operators may be exposed to dangerous concentrations of

hazardous dusts, gases or vapours during operation. Electric
batteries present hazards with acids and hydrogen. Use appropriate
personal protective equipment.
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2. Lift trucks are compact and highly maneuverable and are designed
for handling packaged, boxed, or bagged material or palletized parts
that can be stacked.
3. Attempting to lift more load than the fork lift is designed to handle,
may damage the truck, because tipping of the unit with danger to the
operator or damage the product or building.
4. For safety operation follow the manufacturer's instruction on: viz.

tyre, horn, light, brake, battery, hydraulic system etc.
5. Don't allow riders on the Fork Lift.
6. Face the direction of travel all time. Keep arms legs and other parts
inside cabin.
7. Care must be taken to avoid jerking when tilting a load forward or
backward especially, when the load is at height.
8. When there is a danger of falling objects over the operator’s canopy
guard should be provided.
9. Aisles, floors etc. should be maintained in good condition including

proper lighting.
10. Nobody should stand, cross under elevated forks.
11. Avoid horse play and stunt driving.

12. Park the vehicle with fork flat on the floor, while moving with or
without load keep fork 10 cm above ground level.
13. The capacity of Forklift should be marked on the truck.

14. Don't move a questionable or unsafe load. Avoid Lifting load with
one fork. While lifting, carrying, lowering keep the mast slightly tilted
back, No forward.
15. Due to rear 'wheel steering, the truck tends to swing at the rear. This
is important while turning near edge.
16. While inserting fork, keep mast up right, adjust fork to suit the pallot.
17. Keep an eye on over head projection.
18. In case of fire use CO2 or DPC Fire Extinguishers.
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19. Only trained operators should be allowed to drive forklifts. The
operation of forklifts largely depends on the careful attention of the
operator regarding the passage, the load, the direction of movement,
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and the visibility. Every operator should be familiar with the
maximum load capacity of the fork lift. No extra weight on the rear
should be put to counter balance over load.
20. All starts and stops should be easy and smooth in order to prevent
the load from shifting. They should be operated at a safe speed
smoothly and gradually near the road turnings. While driving fork lift,
the operator should pay special attention regarding the overhead
clearance, fixed structures, electrical conduits and other pipe
installations:
21. While driving the loaded forklifts, the load should not be raised or
lowered in the enroute.
22. While driving empty or loaded forklifts the forks should be carried as
low as possible but high enough not to strike against any raised or
uneven surface. If bulk load is to be carried which cannot be lowered
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enough to prevent its obstructing the view. The operator should drive
the truck backward so that he can see where he is going.
23. When standard forks are used to pick up round objects care should
be taken to see that tips do not damage the load or push it against
others. The mast should first be titled so that < the tips of the forks
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touch the floor and then moved .forward so that the forks can slide
under the Object. To raise the load from the surface on which it is
resting, the masts are tilted backward when rising or lowering loads.
While idle, the operator should not leave the fork lift in gear with the
clutch engaged, instead he should return
24. When the fork lift is not in use, the operator should never leave the
fork lift unattended while the engine is running. He should properly
shut off the machine and remove the starting key and place the load
engaging means in lowered and inoperative position.
25. Parking fork lift on inclined surface should be avoided. However, if it

is necessary, the wheels should be blocked properly.
26. The reverse controls should not be used for breaking and battery
should not be operated beyond their rated capacity.
Check Your Progress
Fill in the Blanks:
1. OSHA defines ______________ as the practice of crafting a job to fit

the employee, rather than the other way around.
2. The ratio between unsafe acts and unsafe conditions in material
handling accidents is _________________.
3. ________________ crane is to be used to lift and move materials and
not to be used as side pulling.
4. A sling that has a ________________ should not be used.

5. The two primary hazards inherent in the operation of lift trucks are
__________________ and Movement or collapse of bridge plates or
other trucks.
Let Us Sum Up
In this Unit you have learnt about the Workers Safety, Material Handling,
Manual Material Handling, Mechanized Material Handling Equipment’s and
Accessories.
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1. ergonomics
2. 4 to 1
3. EOT
4. stretched leg
5. Collision or overturning of the truck
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Unit-5
Safety in Construction
Structure
Overview
Objectives
5.1. Introduction
5.2. Construction Hazards

5.3. Site Security
5.4. Ensuring Safety in Construction site
5.5. Ladder Safety

Check Your Progress
Let Us Sum Up
Overview
In this Unit you will learn about the Introduction to construction site,
Construction Hazards, Material Handling – Manual and by Equipment,
Objectives

 Introduction to construction site
 Construction Hazards
 Material Handling – Manual and by Equipment

 Excavations, Asbestos, Electricity
 Site Security
 Ensuring safety in construction site

 Ladder safety
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5.1. Introduction
A construction site is an area of land where roads, buildings, or some form

of infrastructure are being built or renovated.
A construction site refers to land where all physical construction activities

related to a proposed structure take place. Many people typically use the
term building site is to refer to a construction site. However, the term
building site refers to a site where only housing projects occur, whereas a
construction site is an umbrella term for all kinds of construction.
The landscape properties such as soil and vegetation are modified to
provide a suitable environment for professionals to continue their fieldwork.
A piece of land turns to a construction site when land is handed over to a
contractor to commence construction works.
A construction site does not imply radical changes in a built-in

environment. Even small projects with minimal changes qualify as
construction sites. Construction sites need to comply with the relevant
building regulations as these regulations govern the extent of a construction
site.
Working on a construction site will mean you will be working with or
alongside large operational plant machinery and tools, working at height
and in environments where hazardous materials may be present.
Construction sites are dangerous places of work. Many accidents occur in
construction sites, and employers need to take necessary precautions to
curb the risks in construction sites. There are several plans employers can
put in place to keep projects on track. Below are some of the things you
need to be aware of on a construction site.
Be Aware of Health and Safety Rules:
Every construction site is governed by health and safety rules documented

in the Workplace Safety and Health guidelines. However, these guidelines
are only practical if all the employees are aware of them and adopt them.
Therefore, one should be mindful of these rules, and most employers spend
time educating employees about their responsibilities and how they should
carry them out. The management also ought to listen to employee concerns
and effect appropriate protocols for safeguarding the workplace.
The scenarios in construction sites are constantly shifting, and it is

necessary to evaluate safety plans and implement new ones.
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5.2. Construction Hazards
Here’s a list of construction hazards and guidelines to prevent accidents or

deaths in the industry:-
1. Working at heights:
Working from heights is the most common cause of fatal injuries to workers.
The HSE estimated that 47% of worker fatalities were due to a fall from
height. All employees who work at height need suitable training in working
on different pieces of equipment, and such work must be planned
appropriately. Safety approaches and precautions should be adopted, such
as:
 Where practical, avoid the need to work at height.
 Put collective measures in place where working at height can’t be
avoided to prevent falls. Such as the use of equipment to provide an
extra level of safety to reduce the risk of a fall—for example, a
scaffold with a double guard-rail or edge protection.
 Minimise the consequences of a fall by providing a safety net.

 Wear the necessary P.P.E. such as a safety harness.
2. Moving objects:
The HSE report that 12% of incidents on site are due to being struck by a
moving vehicle or object. A construction site is an ever-changing
environment, with many objects moving around, often on uneven terrain.
Delivery vehicles, heavy plant machinery and overhead lifting equipment
pose a hazard to site workers and operators. Sites should always be
planned to manage plant and pedestrian interface where physical barriers
and suitable segregation is in place.
To reduce risks, workers should:
 Never stand behind large operating plant machinery and never stand
under suspended loads.
 Avoid working close to moving object and be careful of their
surroundings, especially if they do not have lights or beepers.
 Always ensure you have a banksman to guide plant vehicles when

reversing or manoeuvring on a public road.
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 Always wear PPE (Personal Protective Equipment) such as a hard
hat and high visibility jacket to ensure you are seen.
3. Slips, Trips and Falls:
Slips, trips, and falls can happen in almost any environment, and, in
construction, there are slightly fewer incidents of these kinds of injuries than
in other industries. The HSE reports that around a quarter of injuries
reported are due to Slips, Trips and Falls. As construction sites often have
uneven terrain and the typography is forever changing, it is unsurprising that
slips, trips, and falls are a common hazard.
HSE reports that several thousand construction workers are injured every
year following a slip or trip. Most of these could be avoided by effectively
managing working areas and access routes, such as excavations and
footpaths.
Managers and Black hats (site supervisor) on construction sites must
effectively manage the site so that workers can move around it safely. Risks
should always be reported and sorted to reduce the chances of injury. To
reduce harm due to Slips, Trips and Falls, you should:
 Ensure that all operatives are provided with obstruction-free access
and egress to their working areas.
 Keep work and storage areas tidy and designate specific areas for
waste collection.
 Where surfaces are slippery with mud, they should be treated with
stone.
 Where surfaces are slippery with ice, they should be treated with
grit.
 All slippery areas should be signposted, and footwear with a good
grip should be worn.
4. Noise:
Working around loud, excessive and repetitive noise can cause long term
hearing problems, such as deafness. Noise can also be a dangerous
distraction and may distract the worker from the task at hand, which can
cause accidents.
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A comprehensive noise risk assessment should be carried out where the
risk assessment has highlighted a noise hazard with the works to be
undertaken.
5. Hand arm vibration syndrome:
HAVS (Hand Arm Vibration Syndrome) is a debilitating and painful disease

of the blood vessels, nerves, and joints. It is typically caused by the
continued use of hand-held power tools, including vibratory power tools and
ground working equipment.
There are nearly 2 million people at risk of developing HAVS, resulting in
the inability to do fine work, and cold temperatures can trigger painful
attacks on the fingers. Once the damage is done, it is permanent.
HAVS is preventable if construction works are correctly planned to minimise
exposure to vibration during work and workers are monitored are given
appropriate protection when using vibrating tools and equipment.
6. Material Handling – Manual and by Equipment:
Materials and equipment are constantly being lifted and moved around
construction sites, whether manually or by equipment. Either way, handling
carries a degree of risk.
For manual handling, training must be provided to ensure employees can lift
and carry materials safely.
For lifting equipment handling, there are lots of risks, especially when
operating lifting equipment on uneven ground. If an employee is required to
use lifting equipment, they must be trained to operate the equipment safely,
and a regular test should be taken to check their ability to use the
equipment. Always check your plant is fit for use and that it’s certificated
and inspected before use.
7. Excavations:
Incidents commonly occur within excavations on construction sites, such as

an unsupported excavation collapsing with workers inside.
Here are some safety measures that need to be put in place to prevent
excavations from collapse and to reduce the risk of operatives falling into
excavations.
 Never work in an unsupported excavation.
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 Ensure an excavation is supported and fully secure.
 Regularly inspect the excavation both before and during the work
shift.
 Always check that the edge protection of an excavation is 100%

intact before you enter it.
 Always maintain a safe distance from the edge of all deep
excavations.
8. Asbestos:
An estimated 500,000 public buildings in the UK are thought to contain

asbestos. Asbestos kills around 5,000 workers per year, and an average of
20 tradespeople die every week due to past exposure.
Asbestos is a naturally occurring fibre that was used up until the late 1990s
in the UK.
There are three types of asbestos fibres commonly used in the UK, these
are, blue (crocidolite), brown (amosite) and white (chrysotile).
When asbestos is damaged, it realises these fibres into the air, and once
inhaled, these fibres can cause severe and fatal diseases such as lung
cancer, asbestosis, and pleural thickening.
Workers on construction sites must be trained to understand what to do

should they come across any suspicious materials that may contain
asbestos.
If there is asbestos on the construction site, workers must be informed

where it is and how to handle it safely. When handling asbestos, you need
to wear fully regulated PPE equipment at all times to prevent fibres from
being inhaled or absorbed through the skin.
9. Electricity:
HSE reports that 1,000 electrical accidents at work occur every year. Most
of these accidents arise from contact with overhead or underground power
cables and electrical equipment/machinery.
In civil engineering, strikes to services are common. The strikes happen
when excavation is undertaken without adequately checking the ground for
existing services. Consequently, incidents can easily be avoided by using
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technology such as CAT and Genny scanning equipment to scan an area
and foresee potential services and prevent service strikes.
10. Airborne fibres and materials:
Unsurprisingly, a lot of dust is produced on construction sites. This dust is

often an invisible, fine, and toxic mixture of hazardous materials and fibres.
This can damage the lungs and lead to chronic obstructive pulmonary
disease, asthma, silicosis and other such diseases. All employers have to
ensure protective equipment is used.
5.3. Site Security
Having inadequate security around a construction site may danger the

public and lead to an unnecessary incident. Always make sure that
boundary safety fencing is 100% secure and there are no openings for the
public to access.
The Top Safety Hazards in Construction are:
 Working At Height
 Moving Objects
 Slips, Trips, and Falls
 Noise
 Hand-Arm Vibration Syndrome

 Material Handling – Manual And By Equipment
 Excavations
 Asbestos
 Electricity
 Airborne Fibres and Materials.
 Site Security
The leading safety hazards on construction sites include falls, being caught
between objects, electrocutions, and being struck by objects.These hazards
have caused injuries and deaths on construction sites throughout the world.
Failures in hazard identification are often due to limited or improper training
and supervision of workers. Areas where there is limited training include
tasks in design for safety, safety inspection, and monitoring safety. Failure
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in any of these areas can result in an increased risk in exposing workers to
harm in the construction environment.
Falls are the leading cause of injury in the construction industry, in
particularly for elder and untrained construction workers.In the Occupational
Safety and Health Administration (OSHA) Handbook (29 CFR) used by the
United States, fall protection is needed in areas including but not limited to
ramps, runways, and other walkways; excavations; hoist areas; holes; form-
work; leading edge work; unprotected sides and edges; overhand
bricklaying and related work; roofing; precast erection; wall openings; floor
openings such as holes; residential construction; and other walking/working
surfaces.Other countries have regulations and guidelines for fall protections
to prevent injuries and deaths.
Motor vehicle crashes are another major safety hazard on construction

sites. It is important to be cautious while operating motor vehicles or
equipment on the site. A motor vehicle should have a service brake system,
emergency brake system, and a parking brake system. All vehicles must be
equipped with an audible warning system if the operator chooses to use it.
Vehicles must have windows and doors, power windshield wipers, and a
clear view of site from the rear window. All employees should be properly
trained before using motor vehicles and equipment.
Employees on construction sites also need to be aware of dangers on the
ground. Cables running across roadways were often seen until cable ramp
equipment was invented to protect hoses and other equipment which had to
be laid out.Another common hazard that workers may face is overexposure
to heat and humidity in the environment.[citation needed] Overexertion in
this type of weather can lead to serious heat-related illnesses such as heat
stroke, heat exhaustion, and heat cramps.Other hazards found on
construction site include asbestos, solvents, noise, and manual handling
activities
5.4. Ensuring Construction Site Safety
Starting a construction project is exciting and equally stressful. One always

has a lot to learn to ensure the success of a project. Nothing can replace
real-life experience, but we will share below some essential tips to make
your project a success.
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1. Adequate Training:
It is a legal requirement that no worker commence work on a construction

site without site-specific training. There are no similar construction sites,
and therefore the training is always unique to a particular construction site.
The training is always site-specific. It points out high-risk areas in the site,
emergency protocols, and the operation of site-specific equipment. Site-
specific orientation also accompanies the training. This orientation's
objective is to ascertain that everyone has a common purpose on site.
Other goals of the orientation include: -
 Assessing site safety and reporting any new hazards noted

 How to work safely amidst the identified hazards
 Understanding the contractor safety requirements on site
 Understanding safety procedures on equipment theft

2. Personal Protective Equipment (PPE):
According to the OSHA Act, anyone entering a construction site should be
equipped with the necessary PPE (Personal Protective Equipment). PPEs
are the last line of defense when someone encounters hazardous situations
on site. High visibility vests make you easily visible, helmets protect your
head, and safety boots give you grip and reduce your chances of slipping.
Other PPE equipment includes gloves that prevent workers from cuts and
safety glasses that prevent workers from debris in the atmosphere.
Specialized construction might need one to wear protective gear such as
hearing protection and face shields. PPE cannot protect you if you do not
wear it, and you should therefore always wear it on site.
3. Know the construction work's code of practice:
Every construction site has a code of practice approved under law. For
safety purposes, everyone on site should be acquainted with the code of
practice. It offers guidance to identify and manage risks on site. In some
locations, you might come across workers whose first language is not
English. These are referred to as Culturally and Linguistically Diverse
(CALD) workers, and they might need special training on the construction
site's code of practice.
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4. Machinery Maintenance:
The more frequently machinery is inspected and maintained, the less likely
it is to fail. Unexpected component failures can lead to dangerous working
conditions that present environmental hazards. Preventive maintenance
also curbs the expensive downtime brought about by the extra time needed
for repairs. Machines in proper working conditions increase operator
confidence, extend service longevity, and reduce costly litigation times.
5. Tidiness:
In construction sites, workers face many dangers, such as working with

power tools and at considerable heights. Having a cluttered work
environment only works to increase the risks in construction further. For
instance, a fall next to shattered glass or a pile of steel bars would be more
detrimental than a fall next to a clean site. It is also easy for people to move
around, but a site hampered with tools makes navigation risky.
6. Follow Safety Signs:
Due to the numerous potential dangers in construction sites, they should be

appropriately marked for workers with signs proper signages. This warns
anyone nearby to take the necessary precautions. Safety signs are a cost-
effective way of reducing accidents if followed well. Signages with notices
around the site remind the staff of their professional responsibilities. They
give vital information such as emergency kits, first aid kits, and fire
extinguishers. In the case of an emergency, everyone can act to the best of
their ability.
5.5. Ladder Safety
Ladder Inspection Procedure

I. Purpose:
The purpose of this procedure is to establish a plant wide inspection

programme for all portable ladders (step ladders, rolling ladders, single
ladders, scaffolding and scaffold boards).
II. Scope:
 This procedure covers all portable ladders and scaffolding on the

plant.
 Metal ladders will be used on all work requiring the use of ladders
except electrical work.
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 Wooden ladders will be used on all electrical work requiring the use
of ladders.
III. Purchasing:
Step ladder
All step ladders purchased shall be industrial grade and shall not exceed 6
mtr in height. No light duty ladders will be purchased.
Single ladders
 The maximum length of a single ladder shall be 8 meters.

 Nonslip base/feet and a lash rope must be provided on straight
ladders.
Extension ladders
 The maximum extended length of a two section ladder shall not

exceed 12 mtrs. with a minimum overlap of one meter.
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 Extension ladders are to remain intact, not to be separated for use
as a single ladder.
 All locks and guides shall be of metal and of such strength as to
develop the full strength of the side rails. All locks shall be positive in
their action.
 Nonslip bases must be provided on extension ladder.
 The pulley shall be not less than 30 mm in diameter. The rope used
with a pulley shall be not less than 6mm. diameter and having a
minimum breaking strength of 250 kg.
IV. Care Inspection:
All ladders shall have a permanent metal identification tag containing the
ladder number assigned by the Inspection department and the date
purchased. Ladders shall not be painted and when not in use, it will be
stored in designated area.
The following inspection procedure is to be applied to all adders in use.
 New ladders will be included on a three-month nasos after purchase.

 Carefully inspect each ladder for defects such as: broken or no feet,
broken or missing rungs, side rail damage, damaged or missing
pulley, frayed rope, damaged or missing locks on extension ladders,
sharp edges or burrs, all hinge connection, on stepladders, broken
or missing rollers on rolling ladders.
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 Test all rungs are fully, using a light test hammer and striking with a
trip and blow similar to that used by a drummer.
 Test each rung at each end and in the center.
 A "dead" sound will reveal a defective rung or side rail.

 Invariably, failure of the side rails will occur where the rungs or feet
are attached.
 A load test will be performed to determine the conditions of the

ladder: Support the ladder horizontally, gently apply a load of 10 kg.
The ladder must withstand this test with no permanent deformation
or other visible weakening of the structure.
 If a ladder is found unsafe it shall be destroyed immediately upon
authorisation by the Officer or Engineer.
 After a ladder is tested, inspected and found safe it will be tagged

with 12 mm wide colour-coded upon in a visible location.
If a ladder is shortened or repaired, it must meet all of the above
requirements.
Safety Precautions:
No ladder shall be used that does not bear the current inspection band.
- Users of ladders shall visually inspect the ladder before use.

- Ladders with any missing or broken parts shall not be used.
- Defective ladders shall be tagged with "Do not use" and taken to the
salvage yard.
- Straight ladders without safety grip and rope shall not be used.
- Ladders shall not be placed in front of doors opening towards the
ladder unless the door is blocked, locked and tagged, or guarded.
- Ladders shall not be placed on v drums, boxes, or other unstable base
to obtain additional height.
- Ladders shall not be used with the top supported on a window.

- User shall face the ladder when ascending or descending.
- Short ladders shall not be spliced together and used as one.
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- Users of ladders have both hands free to grasp the ladder when
ascending or descending.
- Ladders shall not be used as guys, braces, skids, or for other than their
intended purposes.
- The top step of stepladders shall not be used for climbing or personnel
support.
- The minimum overlap of two-section 12 mts extension ladder is 1

meter.
- Only one person at a time shall be supported by a ladder.
- Metal ladders shall not be, used near electrical wires or by electricians
doing electrical work.
- Ladders shall be handed in such a manner which will prevent exposure
to shock forces (such as dropping).
- Ladders shall not be used in a horizontal position (such as platforms,
runways, or scaffolds).
- When ladders are used to gain access to a roof or platform the ladder
shall extend at least one meter above the edge of the roof or platform.
- Ladders shall be lashed to their support to prevent slipping.
- No one shall adjust or reposition a ladder while being supported by the

ladder.
- No ladder shall be used which has oil, grease or other slippery material
on the steps, or rungs until the contamination has been removed.
- Step ladders shall only be used as designated area.
- The base of straight ladders shall be positioned out from the vertical
support a distance equal to one quarters the vertical distance to the
support.
Check Your Progress
Fill in the Blanks:
1. A ________________ refers to land where all physical construction

activities related to a proposed structure take place.
2. The HSE estimated that _________% of worker fatalities were due to a

fall from height.
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3. Working around loud, excessive and repetitive noise can cause long
term hearing problems, such as ________________.
4. _______________ is a debilitating and painful disease of the blood
vessels, nerves, and joints and it is typically caused by the continued
use of hand-held power tools
5. The acronym of PPE is ______________________.
6. The maximum length of a single ladder shall be __________ meters.

7. The minimum overlap of two-section of a 12 mts extension ladder is
__________ meter.
Let Us Sum Up
In this Unit you have learnt about the Introduction to construction site,
Construction Hazards, Material Handling – Manual and by Equipment,
109
1. construction site
2. 47
3. deafness
4. HAVS (Hand Arm Vibration Syndrome)
5. Personal Protective Equipment
6. 8
7. 1
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SISS-P1: Safety devices – Practical
Exercise-1
Accident Invesgation – Report format
What is an accident report form?
An accident report form is a record of an accident or incident, used to

provide the details of the accident to insurance companies.
Note: This form should be completed whenever an accident or incident
occurs which results in injury or damage to personnel or property. If
personnel or property WERE NOT injured or damaged during the Accident/
Incident, do not use this form. Use the NEAR MISS REPORT FORM.
INCIDENT INVESTIGATION FORM
Directions for Completion:
1. Notify Safety Specialist within 24 hours of incident (Employee Injury,

Near Hit, Property Damage).
2. Complete and submit this form to the designated Safety Office within
3 working days of the accident/Incident.
3. Please remember to sign and date the form.

4. Make five copies of this form for any Lost Time Injury Investigations.
Accident Data/ Contributing Factors/ YesNo/ Employee Injury/ Near

Hit Incident/ Property Damage/ Employee Data/ Employee
Name: ______________________________________________________
Today's Date: ____________________

Department: _________________________________________________
Job Title: _________________________________
Work Area: __________________________________________________

Shift: ____________________________________
Length of Employment at PSU: _________________________________
Full Time Part Time Wage:
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Location of Accident (Building, Room Number): _____________________
____________________________________________________________
Date of accident: _________________
Time of accident: ______________ AM PM

Claim Number: _______________________________________________
Detailed narrative of how incident occurred:
Recommended Engineering control, Training, or Program/policy

change:
Remedial training given: Was a work order or a project request submitted

for solution(s)? Please provide details of request including job/project
number and deadline for completion: What action was or should be taken to
prevent recurrence? Yes/No, If no, explain:
Date:
Recommended Engineering control, Training, or Program/policy change:

Remedial training given:
Was a work order or a project request submitted for solution(s)?
Please provide details of request including job/project number and deadline

for completion:
What action was/ or should be taken to prevent?
Corrective actions completed?

Investigated by:
Date:
Reviewed by:
Date:
112
Exercise 2
Handling and operation of Fire Extinguishers - Type A,
B, C and D
How to operate a fire extinguisher
1. Pull (Pin): Pull pin at the top of the extinguisher, breaking the seal....
2. Aim: Approach the fire standing at a safe distance. ...
3. Squeeze: Squeeze the handles together to discharge the

extinguishing agent inside. ...
4. Sweep.
Types of Fire Extinguishers:
The six main fire extinguisher types are as follows:

1. water
2. foam
3. CO2
4. powder
5. water mist and

6. wet chemical.
Each of the different types of fire extinguisher is suitable for different fire
classes.
Choosing the right fire extinguisher:
The first thing you need to know is the different classifications of fires, and
the second that not all fire, you need to understand what types of fires you
may have to deal with and make sure your extinguisher can get the job
done.
Most household fires fall into one of the following categories:

Class A: These fires are fueled by solid combustibles like wood, paper,
and cloth.
Class B: These fires are fueled by flammable liquids such as oil,
petroleum, and gasoline.
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Class C: These fires are started or fueled by faulty wiring, fuse boxes,
and appliances.
Class K: These fires are started or fueled by cooking oils and greases,
animal fats, and vegetable fats.
All fire extinguishers are labeled to indicate which classes of fire they are
designed to combat. Most household fire extinguishers are considered
multipurpose and labeled for use in A, B, and C classes. Class K
extinguishers are heavier duty and will need to be bought separately. We
suggest this 6-liter extinguisher, as it best fits the Fire Department
Connection’s recommendation.
Fire extinguisher labels also include symbols to indicate which types of fires
the extinguisher is designed to fight. If there is a circle and a red slash
through any of the symbols that indicates that the extinguisher cannot be
used to fight that type of fire.
Household fire extinguishers are also rated for the size of fire that they can
safely handle. The higher the rating (equivalent to the number of gallons of
water it would take), the larger the fire the extinguisher can put out.
 Class A fires are rated 1 to 40.
 Class B fires are rated from 1 to 640.

 There is no size rating for Class C fires.
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Note that higher-rated extinguishers are often heavier, so be sure that you
can comfortably handle the size of the fire extinguisher you keep at home.
Acts during Fire emergency:
Once you understand the different types of fire extinguishers and their uses,
you need to be able to properly operate one.
The best way to be ready for a fire emergency in your home is to study the
steps below and review them regularly so you can protect your home and
family.
1. Identify a clear exit/escape route:
Before operating the fire extinguisher, make sure you have a clear
evacuation path. If you cannot put out the fire, you’ll need to make a safe
exit. Consider this when determining where to store your fire extinguisher,
and make sure you’ll have multiple exit options nearby after you retrieve it.
2. Stand back:
Face the fire and keep your back to the clear exit you earlier identified. You
should stay between six and eight feet away from the flames as you prepare
to operate the fire extinguisher.
3. Discharge extinguisher:
It can be difficult to think clearly during an emergency, so fire safety has a

long-standing acronym to help you recall the steps involved in operating
your fire extinguisher. When extinguishing a fire, you should PASS:
P: Pull the pin on the fire extinguisher.

A: Aim the extinguisher nozzle on the hose low, toward the base of the
fire.
S: Squeeze the handle or lever to discharge the extinguisher.
S: Sweep the nozzle back and forth. Keep the fire extinguisher aimed at
the base of the fire and move it from side to side until the flames are
extinguished.
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Exercise 3
Handling and operation of Hydrant Pipes and hoses
Hydrant pumps:
Fire hydrant pump systems (also known as fire pumps, hydrant boosters,
fire water pumps) are high pressure water pumps designed to increase the
firefighting capacity of a building by boosting the pressure in the
hydrant service when mains is not enough, or when tank fed.
Hydrant Pump
Another model of Hydrant Pump
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Typical Operation:
When a hydrant valve is opened, the system experiences a drop in water
pressure. The drop in water pressure is detected by a pressure switch
which in turn starts the booster pump(s), drawing water from the water
supply to increase the water pressure of the system.
Clapper valve
A New York City hydrant hooked to a fire engine with turgid

hose actively pumping water.
The user attaches a hose to the fire hydrant, then opens a valve on the
hydrant to provide a powerful flow of water, on the order of 350 kPa (50
pounds per square inch gauge (psig); this pressure varies according to
region and depends on various factors including the size and location of the
attached water main). This user can attach this hose to a fire engine, which
can use a powerful pump to boost the water pressure and possibly split it
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into multiple streams. One may connect the hose with a threaded
connection, instantaneous "quick connector" or a Storz connector. A user
should take care not to open or close a fire hydrant too quickly, as this can
cause a water hammer, which can damage nearby pipes and equipment.
The water inside a charged hose line causes it to be very heavy and high
water pressure causes it to be stiff and unable to make a tight turn while
pressurized. When a fire hydrant is unobstructed, this is not a problem, as
there is enough room to adequately position the hose.
Storz connector hose
Most fire hydrant valves are not designed to throttle the water flow; they are
designed to be operated full-on or full-off. The valving arrangement of most
dry-barrel hydrants is for the drain valve to be open at anything other than
full operation. Usage at partial-opening can consequently result in
considerable flow directly into the soil surrounding the hydrant, which, over
time, can cause severe scouring. Gate or butterfly valves can be installed
directly onto the hydrant orifices to control individual outputs and allow for
changing equipment connections without turning off the flow to other
orifices. These valves can be up to 12 inches in diameter to accommodate
the large central "steamer" orifices on many US hydrants. It is good practice
to install valves on all orifices before using a hydrant as the protective caps
are unreliable and can cause major injury if they fail.
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When operating a hydrant, a firefighter typically wears appropriate personal
protective equipment [PPE], such as gloves and a helmet with face shield
worn. High-pressure water coursing through a potentially aging and
corroding hydrant could cause a failure, injuring the firefighter operating the
hydrant or bystanders.
In most jurisdictions it is illegal to park a car within a certain distance of a
fire hydrant. In North America the distances are commonly 3 to 5 m or 10 to
15 ft, often indicated by yellow or red paint on the curb. The rationale behind
these laws is that hydrants need to be visible and accessible in an
emergency.
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Exercise 4
Handling and operation of Form Generators
Foam generators:
Chemguard Standard Model Water Powered (WP) High Expansion Foam

Generators are designed to expand foam solution into millions of tiny
stable bubbles. The continuous flow of the foam solution and the movement
of air through the screen will generate large volumes of foam.
Foam generator
Working of Foam Generator:
Pre-foaming solution and compressed air are fed through a lance which
creates a stiff white foam with a volume 20-25 times that of the pre-foamed
solution. The foam is then mixed into the mortar slurry in a suitable cement
mixer to make EABASSOC Lightweight Foamed Concrete.
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How does foam stop a fire?
A fire is extinguished by removing or interfering with one of the 3 elements

of the fire triangle: heat, fuel and oxygen (air).
Applying firefighting foam on the burning fuel results in suppressing the

oxygen supply. Depending on the foam concentrate type and fire risk faced,
firefighting foam formulation is different. Every firefighting foam includes
surfactants. Surfactants are responsible for the foaming action, foam quality
and wetting ability.
Foam concentrates composition and its Critical Micellar Concentration
(CMC) offer two main properties:
 Wetting property: It lowers the surface tension of water which
spreads quickly over the fuels and penetrates faster in solids than
plain water will. It will deeply cool the solids from inside. Foam
concentrate makes water more effective to suppress a solid fire. The
use of foam concentrate also induces using far less water in class A
and class B fire suppression.
 Foaming property: by adding air inside the foam solution, it forms
foam. Surfactants in the foam produce a lot of bubbles and creates a
stable foam blanket. The firefighting foam produced is very fluid and
spreads quickly and uniformly over the fuel surface. The foam
blanket holds in place for an extended period of time. Water stored
in the foam blanket provides a long cooling effect and reduces the
chance of reignition. The foam blanket separates the fuel and
flammable vapors from the air, so it helps to remove oxygen from the
fire and cut off air supply.
Fluoro surfactants are responsible for the film forming in AFFF (Aqueous
Film Forming Foam) and AR-AFFF (Alcohol Resistant) foams.
On hydrocarbon fires, AFFF foam used generates an aqueous film on the

surface of the fuel. This film is very fluid, it floats and spreads quickly above
the fuel surface. It provides rapid fire control and extinguishment.
On polar solvent fires, AFFF-AR foams are used. Polar solvents fuels are
miscible with water and destroy the foam blanket. That’s why AR-AFFF
foams contain polymers to form a barrier between the fuel surface and the
foam blanket. This barrier protects the foam blanket from destruction by the
polar solvent.
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Fluorine-free foams (FFF) are composed of hydrocarbons surfactants and
are totally free of any fluoro surfactant. There is no film forming property on
hydrocarbon fires. Non-fluorinated foams are composed of an amount of
bubbles that create the foam blanket. The foam blanket quickly controls and
extinguishes the fire. It also forms a polymer barrier to protect the foam
blanket from destruction by the polar solvent.
Drain time is measuring how durable or quick the foam solution will be
released. Longer drain times are required for maximal fuel insulation and
effective suppression.
Firefighting foam quality and performances are tested and approved by

international standards such as EN1568, UL162, NFPA18, LASTFIRE,
GESIP, ICAO, IMO.
Using Foam generator for fire fighting
What is necessary when applying firefighting foam?
Several factors are critical when applying firefighting foam.

First, you must identify the type of fuel and fire risks.
Classes of fire mostly faced by firefighters:

Class A fires: ordinary solid combustibles such as wood, paper, plastics…
Class B fires: flammable liquids
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Water immiscible fuels – hydrocarbon fuels (heptane, oil, gasoline)
Water miscible fuels – polar solvent fuels (acetone, alcohol, isopropanol)
Fire structure and size: for example Structural fires such as solid
combustibles must be deeply penetrated by the foam
Tank: require specific foam equipment (foam pourer or long-range nozzle or
monitor), the foam needs to stick to vertical surfaces.
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Exercise 5
Conduction of Fire Drill
A fire drill is a method of practicing how a building would be evacuated in

the event of a fire or other emergencies. In most cases, the building's
existing fire alarm system is activated and the building is evacuated by
means of the nearest available exit as if an emergency had actually
occurred. Fire drill procedures may vary depending on the building type,
such as hospitals or high rise buildings, where occupants may be relocated
within the building as opposed to evacuating the building. Generally, the
evacuation is timed to ensure that it is fast enough, and problems with the
emergency system or evacuation procedures are identified to be remedied.
Students practicing a fire drill in a smoke trailer with a firefighter

assisting them. This is aimed at teaching the children proper
procedures for evacuating the building in a real life fire or emergency
situation.
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In addition to fire drills, most buildings have their fire alarm systems
checked on a regular basis to ensure that the system is working. Fire alarm
tests are often done outside normal business hours so as to minimize
disruption of building functions; in schools, they are often done when
students and staff are not around or during the holidays where specialist fire
alarm engineers test alarms in the building for repair if needed. Fire drills
often use fire alarms.
A fire alarm notification appliance

Fire drill regulations:
Many jurisdictions require that fire drills be conducted at certain intervals.

This is the case in educational institutions, and also other workplaces and
buildings. The frequency of such drills and what must be done during them
may be laid down in statutes.
How are fire drills conducted?
One of the best ways of fighting fires is by conducting fire drills regularly at
your workplace. Not only does this prepare your employees for such a
situation but it also helps you identify ways through which you can reduce
the damage to life and property.
Fire drills are not only helpful in case of fires. They can also prepare you for
other unforeseen emergencies, such as earthquakes or active shooters.
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Your employees will be well-versed with the evacuation routes and
procedures as a result of the fire drill and will be able to stay away from
harm’s way too. Let’s now take a look at how you can conduct fire drills at
your workplace.
1. Prepare An Evacuation Plan. Before you can conduct your fire
drill, you need to sit down and create an evacuation plan. ...
2. Train Your Employees. ...

3. Communicate The Drill In Advance. ...
4. Rehearse The Drill. ...
5. Rally Point. ...

6. Place Observers.
1. Prepare an Evacuation Plan:
Before you can conduct your fire drill, you need to sit down and create an
evacuation plan. This must be as detailed as possible and should contain all
the exit routes from your workplace. It should also clearly outline the actions
that your employees need to take to reach the rally point.
You may need to consider multiple causes of fires, such as a wildfire, short
circuits, etc. and plan for each of them. The plan must also name the fire
marshal and other key people who’ll help in carrying out the evacuation
procedures. You should highlight their responsibilities in your evacuation
plan too.
The plan must also include a communication plan for emergencies such as
using an emergency mass notification system for a small business or
enterprise company such as RedFlag. It can help you send out alerts
instantly in multiple languages so that your employees can be informed
about the fire quickly.
2. Train Your Employees:
Once you’ve prepared your evacuation plan, you need to train your
employees and introduce them to fire safety. You must put effort into
helping them understand the importance of a fire drill, else, they may not
take it seriously.
Additionally, you should ensure that your entire fire safety team is well-
trained to handle the fire drill. Having a surprise fire drill without preparing
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anyone will lead to no good as people may start rushing through the doors
without following the evacuation plan.
3. Communicate the Drill in advance:
When you’re about to organize your first fire drill, you should communicate
this to your employees in advance. This will prepare them to act in
accordance with the procedures that have already been set. You could use
a two-way emergency mass notification system to effectively send out
these notifications to your employees to demonstrate how active you will
be in soliciting feedback to better direct resources and assistance in the
case of a fire.
You must also set goals for your fire drill and share them with your
employees. These goals can help you identify how well your evacuation
plan works. They could be on the lines of the time taken to evacuate or the
time taken to complete the drill. By measuring these metrics using a
modern emergency mass notification system, you can improve your
performance each time you conduct a fire drill. When you share these
metrics with your employees, they’ll feel equally involved in ensuring their
safety too.
4. Rehearse the Drill:
Before conducting a full-fledged fire drill, you should consider rehearsing it.
This can help in preparing your fire safety team and employees for the
complete drill. The fire safety team will be able to understand their
weaknesses by conducting these mock drills.
Employees, on the other hand, will be able to master the basic fire drills
before moving on to the more complex ones. You can keep changing the
variables during these mock drills to train your staff on how to react during
different scenarios.
5. Rally Point:
Rally points are of prime importance during any fire emergency. These are
safe points where employees need to gather after evacuating the premises.
Here, the fire safety team needs to cross-check if every employee has
made it out of the fire area safely.
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Sign board at Rally point
This rally point is typically placed outside the building to ensure that it’ll be
away from any fires. In the case of a large organization, it’s common to
have multiple rally points with different leaders from the fire safety team at
each point.
After the counting of employees has been done at the rally points, the
leaders should ascertain if any employees are missing. These should then
be reported to the professionals in charge immediately so that appropriate
action can be taken according to the established protocols.
6. Place Observers:
The last step in conducting a fire drill at your workplace is that of placing
neutral observers. These people shouldn’t be a part of your fire safety team
and their role would be to observe the entire drill. They can help you identify
loopholes in your fire evacuation plan or non-adherence to it as well.
Employees who are moving slowly in groups or are on their cell phones
during the evacuation process can be identified by them. These observers
can present their observations post the fire drill and based on these,
appropriate actions can be taken.
Other considerations to improve Fire safety:
Here are some other things to consider as you plan for your fire drill at work:
 Work in various realistic scenarios for future drills such as “this
hallway is on fire” or “this door won’t open.”
 As new employees are on-boarded, their new manager could handle

a simple walk-through of their evacuation route.
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 Conduct drills at random times to simulate a real-world scenario and
improve overall preparedness.
 Companies with extensive chemicals and equipment should ideally
conduct drills every three months. For most everyone else, twice per
year is adequate.
 If a key fire safety leader leaves the company, make sure to replace
them immediately and then do a leaders-only walkthrough of the fire
drill procedures.
Fire evacuations are serious situations to prepare for. And with the health
and safety of your team at stake, getting it right by thorough planning is
critical. As long as you are clear with your employees about what is
expected of them and how it will benefit them, everyone will appreciate the
effort to make your drills efficient and professional. And everyone will be
confident about how to exit the building safely in the event of a fire.
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Exercise 6
Handling of LPG and other gas cylinders - safety
This exercise provides basic guidance on the safe storage and handling of
compressed gas cylinders. These guidelines need to be followed in order
to protect people, property and the environment from emergencies
involving gas cylinders as well as ensuring compliance with relevant
legislation.
These guidelines apply to all workers and others who store and
handle gas cylinders at the University of Wollongong.
Definitions:
Asphyxiation: Deprivation of oxygen that can result in unconsciousness

and often death.
Flammable gas: A gas that can be ignited in air. A flammable gas is a gas
that burns in the presence of an oxidant when provided with a source of
ignition. Flammable gasses can include methane, acetylene, ammonia,
hydrogen, propane, and propylene. The risk of a fire starting increases in
relation to the amount of gas present. If the concentration exceeds the
higher value (UEL), the air will become too rich to burn, which will actually
reduce the chance of ignition. OSHA does not categorize aerosols as
flammable gases.
Inert or Noble gas: An inert gas is a gas that does not undergo chemical
reactions under a set of given conditions. The noble gases often do not
react with many substances and were historically referred to as the inert
gases. Inert gases are helium (He), neon (Ne), argon (Ar), krypton (Kr),
xenon (Xe), radon (Rn), and oganesson (Og). The noble gases are
colourless, odourless, tasteless, nonflammable gases. These gases are un-
reactive except under certain special conditions.
Non-flammable gas: A gas that is neither flammable nor poisonous but can
still cause asphyxia and death.
Oxidizing gas: A gas that initiates or promotes combustion of materials
through release of oxygen. These gases can also spontaneously
combust/explode.
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Short Term Exposure Limit (STEL): Maximum concentration of a gas
that a person can be exposed to for a 15 minute period. Only 4 such
exposure periods can occur within an 8 hour day and 1 hour break is
required between exposure intervals.
Time Weighted Exposure Limit (TWA): Maximum concentration of a
gas that a person can be exposed to for 8 hours per day over a 5
day working week.
Toxic gas: A gas that is poisonous or capable of causing injury or
death, especially by chemical means.
Upper and Lower Explosive Limits (UEL and LEL): Upper and lower
concentration (in %) limits for which a particular gas is explosive in air.
Types of Gases:
There are three types of gases commonly supplied and used:

1. Compressed Gases – Nitrogen, Oxygen, Air, Carbon Dioxide,
Helium
2. Liquefied Gases – LPG, Liquefied Nitrous Oxide

3. Dissolved Gases – Acetylene Cryogenic vapour could also be
considered as a gas but is dealt with in a separate document.
Refer to Storage, Transport and Handling of Cryogens Guidelines for

information on vapour from cryogens. HRD-WHS-GUI-429.2 Storage and
Handling of Gas Cylinders Guidelines 2015 December Page 2 of 14
Hardcopies of this document are considered uncontrolled. Please refer
to UOW website or intranet for latest version.
Storage of Gas Cylinders:
Ventilation: All gas cylinders should be stored in a ventilated area. All

gases may act as asphyxiant by displacing the natural oxygen in the air,
ventilation acts as a precaution against this potential hazard.
Storage Temperature: Cylinders should not be stored or exposed to
temperatures above 120º F (51.7 ºC) -- especially those that do not have a
pressure relief device (PRD), such as cylinders containing poison gases.
Storage Separation: In storage, oxidizing gases such as Oxygen, Nitrogen
Dioxide and Nitric Oxide, must be separated from flammable gases or
combustible materials (oil or grease). The minimum distance of separation
131
is 20ft, unless there is a non-combustible barrier, like a concrete wall,
between the cylinders.
Shelf lives:
 Some gases have relatively short shelf lives
 Some corrosive gases should not be stored longer than 6-8 months.
132
For more information about shelf lives of specific gases consult your gas
supplier.
Transportation and Handling:
 Cylinders that contain compressed gases should not be subjected to

rough handling or abuse.
 When moving a cylinder remember to:
o Remove regulator and put safety cap before transport.

o Cylinders must NOT be slid or rolled.
o Secure cylinders to cart.
Personal Protective Equipment (PPE):
 Wear protective equipment appropriate for the potential hazard of

the material you are working with.
 Eye protection: safety glasses or face shield and splash goggles.

 Protective clothing: cryogenic gloves, lab coat and closed toe shoes.
Opening / Closing Cylinder Valve:
 The cylinder should be placed so that the valve handle at the top is
easily accessible at all times.
 Open the valve slowly- never leave a valve part open, either open all
the way or close it all the way.
 The cylinder valve should never be left open when equipment is not
in use- air and moisture can diffuse through the valves causing
contamination and even corrosion within the cylinder.
Leak Check
Leak detection procedures should be implemented prior to use of any

system using compressed gases. This can be accomplished by doing the
following:
 For flammable gases, a soapy water solution or a 50% glycerin-
water solution should be used. "Snoop" available from University
Stores or your gas supplier, may be used for this purpose; Bubbles
will indicate a leak.
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 For systems where toxic or corrosive gases will be used, first
conduct a leak check of the system with an inert gas (i.e. argon,
nitrogen) before introducing the toxic gas in the system.
Cylinder Disposal:
A cylinder is considered empty when the pressure in the cylinder is

approximately 15-30 psi. To dispose of empty cylinders or viable cylinders
that are no longer utilized, the following steps should be taken:
1. Remove regulator from cylinder and put the safety cap on.
2. Move cylinder to storage area for empty cylinders.
3. Fill out Cylinder Return Form to return to the gas supplier.

 Refillable cylinders should be directly returned to the
respective supplier.
 Submit a pickup request to dispose of cylinders only if
disposal through the supplier is not possible.
Keep in mind: Never empty a cylinder completely. This will prevent a flash
back into the cylinder and contamination into the cylinder and a possible
explosive mixture.
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Exercise 7
Safety measures, inspection checks for conveyors and
cranes
What is the safety needed before operating conveyors?
Keep conveyor surroundings clear of debris and clean up any lubricant

spills before working on a conveyor or restarting it. Always replace safety
guards before placing a conveyor back into service. Never operate a
conveyor with an open or missing chain or belt guard.
Conveyor operating panel
Conveyors are very helpful in moving material and supplies within a facility.
However, they are a common cause of injury in a plant. We’ve compiled this
list of safety practices that will help keep you and your coworkers safe.
1. Don't sit, stand, or walk on conveyors:
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 Conveyors are never meant to be occupied by a person.
 Conveyors have many features, including pinch points that can
catch clothing or people and cause serious injuries.
 A limb stuck in a pinch point can be severely damaged or even torn

off.
 Industrial conveyors are not designed for people so you should
never ride on conveyors.
2. Make sure conveyor controls are operating correctly:
 Controls that don’t work properly can cause serious problems.
 Inspect your conveyor controls to make sure no employee has

misused, modified, or disconnected them.
 Controls should be easy to read and use, as well as easily
accessible.
 Place emergency stops in highly visible and accessible locations.
3. Keep hair, clothing, jewelry, and other loose items away:
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 Conveyors can catch loose clothes or long hair, resulting in severe
injuries.
 Make sure long hair is tied back or tucked under a cap.
 Don't wear bracelets, rings, watches, or other jewelry.

 Avoid wearing baggy clothing; remove ties or tuck them into your
shirt.
4. Check that all conveyor guards are in place:
 Don’t operate a conveyor if guards are not securely mounted.

 Conveyors contain gears, chains, belts, and other moving parts that
can be hazardous if exposed.
 Employees should not be able to bypass, remove, or alter conveyor
guards.
 Guard openings should be small enough to keep workers from

entering danger zones.
5. Be watchful of pinch points:
137
 Conveyors are filled with pinch points by their very nature.
 Conveyors contain gears, chains, belts, and other moving parts that
can be hazardous if exposed.
 Employees should not be able to bypass, remove, or alter conveyor

guards.
 Guard openings should be small enough to keep workers from
entering danger zones.
6. Alert management of any potential safety or operational concerns:
 If you see something, say something.

 The best way to correct an unsafe situation (e.g. loose guards, a
person riding the conveyor) is to alert the person responsible for the
area.
 Make sure it is clear who the point of contact is and how to reach
that person.
 Training about safety issues and when to report them should be
made available to all employees.
7. Follow lock-out/tag-out procedures:
138
 Failure to do so exposes employees to life-threatening injuries.
 Secure conveyor systems before maintenance or repair by following
proper lock-out/tag-out procedures.
 Lock-out/tag-out procedures prevent equipment from being powered

up while maintenance or repairs are being done.
 Conveyor operators must be properly trained to perform lock-
out/tag-out procedures.
8. Allow only authorized personnel to operate or maintain the
conveyor:
 This ensures technician safety and optimal conveyor performance.

 Material handling equipment can be dangerous to those who do not
understand how to safely work on it.
 When something needs to be fixed, contact your trained

maintenance person.
 Only those employees who are trained to operate and perform
maintenance on conveyors should do so.
Crane Safety
A crane is a machine used for lifting and lowering a load and moving it
horizontally, with the hoisting mechanism an integral part of the machine.
Overhead cranes are used in many industries to move heavy and oversized
objects that other material handling methods cannot. Overhead cranes have
a railed support structure, known as a bridge, and a wheeled trolley that
travels across the bridge horizontally. The other primary component of an
overhead crane is the hoist, that’s attached to the trolley, and is used to
perform the lifts.
Mobile crane incidents can cause massive production delays, devastating
property damage, and loss of life. OSHA estimates that 89 crane-related
fatalities occur each year in construction work, and many of these are high-
profile events that receive a lot of adverse publicity. It is likely that many
fatalities could have been avoided with proper mobile crane lift planning.
139
Safety Precautions:
 The rated load of the crane must be plainly marked on each side of
the crane - if more than one hoist is present, each hoist must have
its rating shown
 Clearance must be maintained above and to the side of cranes
 Walkways cannot be placed in a crane operating zone that would
compromise employee safety when the crane is in operation
 Parallel cranes must have adequate clearance between the two
bridges if no walls or structures are between them
 Only designated personnel are permitted to operate a crane

Inspection Requirements:
Due to the size and weight of the objects often being lifted and transported
by overhead cranes, routine inspections are necessary to ensure continued
safe operation. An initial inspection of the crane (new or altered) prior to
initial use is required. Once placed into service, overhead cranes require
two different types of inspections. Frequent inspections are done daily to
monthly, while periodic inspections are completed at monthly to annual
intervals. The purpose of the two inspection types is to examine critical
components of the crane and to determine the extent of wear, deterioration
or malfunction.
Frequent Inspections:
Items to be Inspected Frequency
Functional operating mechanisms for maladjustment Daily
Deterioration or leakage in lines, tanks, valves, drain

Daily
pumps and other parts of air or hydraulic systems
Hooks with deformation or cracks (visual) Daily
Hooks with deformation or cracks (written record with

Monthly
signature of inspector and date)
Hoist chains and end connections for excessive wear,

twist or distortion interfering with proper function, or Daily
stretch beyond manufacturer's recommendations
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Hoist chains and end connections for excessive wear,
twist or distortion interfering with proper function, or
Monthly
stretch beyond manufacturer's recommendations
(written record with signature of inspector and date)
Running Rope and end connections for wear, broken

strands, etc. (written record with signature of inspector, Monthly
rope identity and date)
Daily to
Functional operating mechanisms for excessive wear
Monthly
Rope reeving according to manufacturers' As

recommendations recommended
Periodic Inspections:
Items to be inspected:
 Deformed, cracked or corroded members
 Loose bolts or rivets
 Cracked or worn sheaves and drums

 Worn, cracked or distorted parts, such as pins, bearings, shafts,
gears, rollers, locking and clamping devices.
 Excessive wear on brake-system parts, linings, pawls and ratchets

 Inaccuracies in load, wind and other indicators
 Electric , gasoline, diesel, or other types of motors for improper
performance
 Excessive wear of chain drive sprockets and excessive chain stretch
 Deteriorated electrical components, such as pushbuttons, limit
switches or contactors
In addition to the initial inspection, OSHA also requires that all new and
altered crane-functions are tested for:
 Hoisting and lowering

 Trolley travel
 Bridge travel
 Limit switches, locking and safety devices
141
Standard Hand Signals for Controlling Overhead and Gantry Cranes:
142
Exercise 8
Safety measures, inspection checks for excavation
Excavation:
Excavation failures are particularly dangerous because they may occur

quickly, limiting the ability of workers (and in some cases others nearby) to
escape, especially if the collapse is extensive.
The speed of an excavation collapse increases the risk associated with this
type of work. The consequences are significant as the falling earth can bury
or crush any person in its path resulting in death by suffocation or internal
crush injuries.
1.1 Scope and application
This guideline is for persons conducting a business or undertaking

(PCBUs), workers, upstream PCBUs, and competent people involved in
excavation work.
All work involving excavations must comply with the requirements of the
Health and Safety at Work Act 2015 (HSWA) and all relevant regulations,
including the Health and Safety in Employment Regulations 1995 (the HSE
Regulations) and the Health and Safety at Work (General Risk and
Workplace Management) Regulations 2016 (the GRWM Regulations).
This guideline does not apply to shafts associated with mining operations,
or tunnelling operations, which are regulated under the Health and Safety at
Work (Mining Operations and Quarrying Operations) Regulations 2016 (the
MOQO Regulations).
For more information on the specific regulations relating to excavation work,
see the relevant Legal framework.
Some industries have guidelines that deal with specific problems faced in
their working environments, such as the electricity sector or plant and
machinery hire. When deciding how to do a job safely, make sure to check
any industry specific guidance.
143
What is excavation work?
Excavation work generally means work involving the removal of soil or rock
from a site to form an open face, hole or cavity, using tools, machinery or
explosives.
Excavation work can occur anywhere, including:
 on construction sites
 on business premises
 in public areas.
Excavation work includes:
 open excavations
 potholing
 pit excavations
 trenches and retaining walls

 shafts and drives
Open Excavations: An excavation in open ground is an open excavation
and can vary in shape and size.
Open excavation
Potholing: Potholing is usually a small excavation or inspection hole to find
underground services.
144
Pot hole
Pit Excavations: Pit excavations are usually four-sided and deeper than
the narrowest horizontal dimension at the surface.
Pits are generally excavated to install manholes, pump stations, or

underground tanks. They are also excavated to construct pile caps and
other types of foundations or to access or locate existing services.
Pit excavations
Trenches and Retaining Walls: A trench is a long narrow excavation
which is deeper than it is wide, and open to the surface along its length.
Trenches are generally excavated to install or maintain underground

services or to investigate what is beneath the surface.
145
Trench
When a retaining wall is built, an open excavation becomes a trench formed

by an excavated face on one side, and a retaining wall on the other. Usually
workers need to access this trench to work, for example for waterproofing
the retaining wall.
Trench constructed by putting up a retaining wall
146
Shafts and Drives: Sinking a shaft involves constructing a vertical
excavation with access and spoil removal from the top.
Drives are small openings cut into the sides of trenches or shafts or
elsewhere, for example, under roads. Cutting a drive is particularly
hazardous as it introduces the risk of trapping workers with no alternative
escape route.
Shafts and drives are often constructed to provide access or ventilation to a

tunnel. Shallow shafts can be sunk for investigating or constructing
foundations, dewatering, or providing openings to underground facilities.
Shaft
What are the Hazards in Excavation?
“As any man-made cut, cavity, trench, or depression in the Earth’s surface
formed by earth removal,” according to the OHSA definition, excavations
involve many hazards. Here are some of the dangers brought by
excavations:
 The collapse of the sides of the excavation.

 Materials falling onto people
 Falls, either people or vehicles.
 Nearby structures collapsing into the excavation.
147
 Electrocution, explosion, gas leak, or flooding, caused by damage to
underground services.
An OSHA investigation reported that the main reason why trenches collapse
is that they are not properly protected. Protective systems such as sloping
the ground, benching the ground, shoring the trench with supports such as
planking or hydraulic jacks, and shielding the trench using a trench box
should be properly implemented at all times. Other excavation safety
measures include:
 Collapsing should be avoided by supporting the sides by either
battering them or supporting them with sheets.
 Materials from the excavation should be stored at a safe distance
from the excavation, this will help reduce the risk of them falling onto
people.
 Adding barriers to excavation is an essential precaution to avoid
people falling into the excavation.
 It is safer if vehicles are kept completely out of the excavation area,

but if required the use of barriers and stop-blocks should help
mitigate that danger.
 Cable, pipe, and service plans should be used to ensure that

underground services are known so they can be marked on the
ground or, ideally, the area avoided entirely.
 Around the areas where there are underground services, mechanical

equipment should be avoided and instead use spades and/or
shovels.
 Picks and forks should be avoided as they are more likely to pierce
cables and pipes.
 Flooding can be avoided by ensuring that there is appropriate
pumping equipment so that any water that seeps into the excavation
can be easily pumped out to a safe area.
What precautions must be taken to protect employees during
excavation work?
According to the Construction Regulations, precautions must be taken that

are adequate to:
148
 Guard against danger to persons at work from a fall or dislodgement
of earth, rock or other material by suitable shoring or otherwise
 Guard against dangers arising from the fall of materials or objects or
the inrush of water into the excavation, shaft, earthworks,
underground works or tunnel
 Secure adequate ventilation at all workplaces so as to maintain an
atmosphere fit for respiration and to limit any fumes, gases, vapours,
dust or other impurities to levels which are not dangerous or
injurious to health
 Enable persons at work to reach safety in the event of fire or an

inrush of water or materials
 Avoid risk to persons at work arising from possible underground
dangers such as underground cables or other distribution systems,
the circulation of fluids or the presence of pockets of gas, by
undertaking appropriate investigations to locate them before
excavation begins
 Ensure that a safe means of access to and egress from each
excavation
149

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Tamil Nadu Open University

School of Continuing Education

Short-Term Course in Industrial

SISS-1 & P1: Industrial Safety and

June 2022 (First Edition)

Total no. of pages: 149

@ TNOU, 2022, “Industrial Safety and Security” is made available under a

Unit No. Title Page

SISS-T: Industrial Safety and Security-Theory

Unit-1 Principles of Safety Management 4

Unit-2 Industrial Safety, Health and Environment Act 19

Unit-3 Fire and Electrical Safety 46

Unit-4 Material Handling and Safety 74

Unit-5 Safety in Construction 95

SISS-P: Industrial Safety and Security-Practical

Exercise-1 Accident Investigation – Report format 111

Exercise-2 Handling and operation of Fire Extinguishers – 113

Exercise-3 Handling of Hydrant pipes and hoses 116

Exercise-4 Handling and operation of Foam Generators 120

Exercise-5 Conduction of Fire Drill 124

Exercise-6 Handling of LPG and other gas cylinders - Safety 130

Exercise-7 Safety measures, inspection checks for 135

Exercise-8 Safety measures, inspection checks for 143

The Short-Term Course in Industrial Safety and Security covers both

Exercise-1 Accident Investigation – Report format

1.2. Objectives of Industrial Safety

1.5. Common Causes of Workplace Accidents

Check Your Progress

After learning this Unit, you will be able to understand about:

 Industrial Safety Planning

Industrial safety is defined as policies and protections put in place to ensure

 Process and production safety

 Building and structural safety (including temporary installations)

1.2. Objectives of Industrial Safety

 Preventing work-related fatalities, disabling injuries, illness, and

1.3. Industrial Safety Planning

 Health and hygiene

The thousands of industrial accidents every year caused the realization of

1. Obey Safety Requirements:

Another way to help prevent accidents on the job is to be in constant

Faster isn’t always better, especially when safety can be jeopardized. Do

Outside of bodily harm, workplace accidents present a number of

First, workplace accidents can lead to a loss of productivity. If a worker is

Preventing accidents and creating a culture of safety awareness are the

 11% involved overexertion in lifting or lowering.

1.5. Common Causes of Workplace Accidents

One of the cornerstones of safety awareness is understanding what unique

 When assessing the cases reporting these accidents, the CDC

 13% of falls on the same level are from slips.

The best way to avoid workplace accidents is through a strategic safety

 Promote safety awareness and education with regular safety

 Communicate safety hazards with adequate signage that clearly

 Contain spills quickly when they happen, and remember to always

 Install proper ventilation to prevent toxic chemicals or other foreign

In the event of an incident, immediate action to be taken may include

Planning ensures that the investigation is systematic and complete. What

The investigation is concluded when all outstanding issues have been

1.7. Workplace Safety Training and Meetings

The Industrial Safety course programme teaches students all practical

 Computer skills − Computer skills are becoming an essential for