1 “ Safety in Construction ” Prakash Nirwan 28 th June’12, Hotel New Marrion, Bhubaneshwar SAFE KONNECT 2012 “Moving ahead in Industrial Safety” Confederation

1

“Safety in Construction”

Prakash Nirwan

28th June’12 , Hotel New Marrion, Bhubaneshwar

SAFE KONNECT 2012“Moving ahead in Industrial Safety”

Confederation of Indian Industry

Presentation on

2

• Background & Importance of Safety in Construction

• Project details for 6 Mtpa at Tata Steel, KPO

• Tata Steel’s initiatives in Construction Safety

Contents of the Presentation Pack

Importance of Construction Projects

The Construction industry is an important indicator of the development:

•Creates investment opportunities across various related sectors

•Contributes in Economy Growth (Approx. 10 % in Developing Countries' GNP)

•Major Employment Generator

At the same time it is also associated with proportionately high number of job-related

accidents due to:

•Labour intensive nature

•Continuously changing working environments

•Involvement of several different agencies

•Custom of employing migrant farm labour from lower-wage economies for short term

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Importance of Construction Projects

Thus addressing Construction Safety Performance and the

safety of the workers in the construction industries can have

a great impact on:

•Reducing injuries

•Cost associated with safety

•Project delays

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Challenges of Construction Industry in India

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Construction Activities

Competent Manpower

Safety Awareness

Training Infrastructure

Labour Camps

Unorganised Sector

Socio-Economic ProblemsCultural Gaps

Environmental Impact

assessment

Social Hazards at Site

Source: Godrej : Safety Control in Construction Industry

Study Result of 1996 in UK shows….

1. The construction industry had:

15 victims per 1,00,000 workers as compared to

4 per 1,00,000 workers in all other industries combined

1. The frequency of disabling injuries in construction industry

5300 per 1,00,000 as compared to

3100 per 1,00,000 in all other industries

“The records of the last 45 years confirm the trend that the

Construction Industry has VERY high fatalites and injury rates.”

6 Source: European Journal of Scientific Research

Accident Statistics during Construction

Helander (1991) in examined 739 construction deaths that occurred in the

UK based on the following categories used for classifying fatal accidents :


Key Factors in Accident Prevention

Based on Model Survey analysis, the Six Most Important

factors in Accident Prevention are:

1.Maintaining Safe Work Conditions

2.Establishing Safety Training

3.Safety Education to support good safety habits amongst workers and

supervisors

4.Effective Control of the main contractors on site

5.Maintaining Close Supervision of all work

6.Assigning Safety Responsibility to all levels of management and workers


Key findings of study on Accident Prevention

Study focusing on Middle Level Management found that:

•Management attitudes have more influence on Safety than the foreman or

peer groups

•Workers work more Safely for a supervisor who respects his men and

their contribution

•Better co-ordination improves Safety

•Work on piece rate basis rather than a fixed hourly basis increase the

probability of accidents


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MOU Signing Between Tata Steel and Govt. of Odisha on 17th November’04

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NINL

MESCO

Jindal Stainless

Rohit F/A

VISA

Jakhapura Rly Station

Tata Steel

Plot-1Plot-2

BRPL

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Major Production Units Capacity/SizeRaw material handling system 19 mtpa raw materialsCoke oven by-product plant: 4 Batteries 2.8 mtpa Gross CokeSinter plant 496 sqmPellet plant 4.25 mtpa Blast Furnace 2 x 4300 cu mLime Calcining Plant 3 x 600 tpdSteel Melt Shop 6 mtpa slabHot Strip Mill 5.5 mtpaCold Rolling Mill 2.2 mtpaCaptive Power Plants:-By-product Gas Based-Coal based

3 x 67.5 MW3 x 150 MW

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•Lack of Industry Culture (Safety Knowledge & commitment)

•High proportion of unskilled & temporary workmen

•Transient nature of contract workers during construction

activities (Frequent Work Team rotations)

•Exposure to weather conditions (Extreme Hot, humid &

stormy)

•Indiscipline (Personal Behaviour)

•Societal issues (Intoxication habits)

Challenges in Green Field Project

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Safety Management System at Tata Steel

Apex Safety Committee

Divisional Implementation Committee : KPO

Area Implementation Committees (20)

Sectional Implementation Committees (@ 50)

Training &

Communication

Safety Standard

Incident Analysis

OHSProcess Safety

Contractor

Mgmt.

Observation & Audit

Incident A

nalysis

Road and R

ail Log

istic

OH

S &

E

nvironm

ent

Observation & Audit

Road & Rail

Safety

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Safety Organization Focus Areas

(DuPont Methodology to achieve World Class Standards)

A) Line Management Accountability & Responsibility

B) Construction & Contractor Safety Management

C) Process Safety Risk Management

D) Rules, Procedures & Performance Standards

E) Positive Isolation

F) Safety Observation and Audit

G) Incident Investigation & Analysis

H) Road & Rail Safety

I) Occupational Health & Environment

J) Training & Communication

K) Consequence Management & Motivation

World Steel Survey-Critical areas(based on Fatal) FY11

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80% of these causes are applicable in construction phase

Total 120 Nos.

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Activity / Process

Hazards associated Means to address Hazard

Measures

Fool Proof Fail Safe Fail Soft

Material Falling / Material Handling

Crush, impact, hit

injury

Monitoring & control of overloading of trucks, dumpers etc.

Toe guards to scaffolding (for arresting material falling from height)

Practice of chain lashing with necessary fixtures like bracket, D-Shackles, turn buckles as per Transportation Safety Standard

Working at Height

Fall from height,

Injury due to falling objects

Adherence to Barrication Standard at excavated pits

Working platforms, life line, Use of double lan-yard harness, fall arrestor and safety net

Compliance to Scaffolding Standard

Issue of Height Pass based on medical test

Isolating work place under working at height

Action Plan: Material Handling & Working at Height

Chain lashing with fixtures during transportation

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23/05/12 23/05/12

Working Platform and Lifeline

Fail Soft: Working Platform & Lifeline

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Use of Safety Nets

Use of Safety Nets during Structure Erection

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Use of Full Body Harness and Double Lanyards

Working at Height : Safe Soft Methodology

Compliance Monitoring of Scaffolding Safety

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Visual Display of Scaffolding Checking

Status

Safe Access for working at height

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Material Handling using Tower Cranes

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Action Plan: Heavy Vehicles / Mobile Equipment’s movement

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Activity / Process

Hazards associated Means to address Hazards

MeasuresFool

ProofFail Safe

Fail Soft

Heavy Vehicles / Mobile

equipment's movement

Hit, dash, collision, run-over

Helperless Driving

Use of reflective stickers to heavy vehicles

Separate walk ways for pedestrian within each site Flag man to guide heavy mobile vehicles Access control thru physical barriers

Mandatory use of high visibility jackets Rest rooms near workplace at site

Side & Rear Run under protection guards to heavy vehicles

Weekly monitoring of illumination level

Heavy vehicle fitness checking thru weekly audits

Pedestrian Walkways within sites

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Run-over Protection Guards & Flagman

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Use of High visibility jackets & other PPEs

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Heavy Vehicle & Mobile Equipment Safety

Use of Reflective Stickers Heavy Vehicle Audits

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Activity / Process


Measures


ElectricalElectrocution, Injury due to Electric Flash

Compliance to Temporary Electrical Wiring standard

Implementation of Positive Isolation

Earthing of tools, appliances and equipments

Goal Post below HT lines

Fire extinguishers and rubber mat at Electrical DB rooms

Moving Machinery & Stored Energy

Hit, crush, entrapment

Guarding of chains and rotating parts

Maintaining safe distance between moving material and rigger

Presence of Flag Man for earth moving equipments and heavy vehicles

Action Plan: Electrical & Moving Machinery Hazards

Fool Proof : Goal Post below HT line crossing

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Placement of Rubber Mat in front of Electrical Panels

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Activity / Process

Hazards associated Means to address Hazards

Measures

Fool Proof

Fail Safe Fail Soft

Road Safety

Crush, hit, dash,

collision, run-over

Road Safety Awareness Campaigns

Audio-visual alarms & signage

Deputing Road Traffic Volunteers / Flag Men

Restricted movement of two wheelers inside site

One way traffic inside site

Access control system (Safety Induction Pass System)

Training on defencing driving to drivers

Audits for intoxication checking for drivers

Speed Monitoring camera inside site

Action Plan: Improve Road Safety

Road Safety Initiatives

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Speed barriers at junction pointsDeployment of Flagman

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Road Safety

Display of Road Safety Signage & Directional Board (One Way Traffic)

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Activity / Process


Measures


ExcavationFall from height,

entrapment

Hard barrication to excavated pits and use of net

Periodic Excavation Inspection Report for monitoring Slope Ratio, Shoring, Shielding, Barricades, Water Removal and Over burden at edge

Monitoring stability of earth moving equipments

Use of rebar caps for improved visibility & to protect sharp edge

Verification of excavation safety standard thru Checklist

Action Plan: Safety during Excavation

Hard barrication & benching at Excavated Pits

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Use of Rebar Caps

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Activity / Process


Measures


Fire ManagementHeat / Burn

injury

Hot work checklist

Fire Fighting Training

Audits for Fire Safety

Fire Tenders and Extinguishers

Confined SpaceGassing,

Poisoning, Asphyxiation

Compliance to Confined Space Standard

System of gas detection and impact assessment

Work Permit for Confined Space

Action Plan: Fire Management & Confined Space

Fire Fighting Training & Demonstration

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Spatter Protection while Hot Work at Height

Display of Emergency Contact Numbers and Communication

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23/05/12 23/05/12

Employee Recognition

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Safety Communication in Local Language

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Safety Communication in Local Language

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Let’s join hands

to make SAFETYSAFETYa way of Life….!!

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Thank You

Journey Continues…..!

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Back-up Slides

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Project Phase

Risk Review Phase Name

Goals of Risk Review Risk Review Methodology

1&2 ConceptualChoosing inherently safer option, ensure overall feasibility, estimate impact on neighbours

- Consequence modelling- What-If (no guidewords)- Selected checklist for judging inherent safety

3 Preliminary Design

Identify & resolve most expensive design alternatives, including layout of plant, facility siting concerns, environmental protection issues and major tie-ins

- What-if (no guidewords)- HAZOP / FMEA of selected scenarios- Layers of Protection Analysis (LOPA) of selected scenarios

4 Detailed Design

Identification of potential accident scenarios, preliminary focused on normal mode of operationBegin risk assessment for scenarios with large residual risk

- HAZOP / FMEA of equipment nodes, focusing on normal mode of operation- What-if of lower consequence & lower complexity systemsLOPA of 1-5% of the scenarios: Determine Safety Integrity Level (SIL)

5 Final Design

Update results of previous Risk Review for new details, identify potential accident scenarios for nodes not previously reviewed, primarily focused on normal mode of operation. Resolve most previous recommendationsComplete risk assessment for scenarios with large residual risk

- Complete HAZOP, FMEA or what-if for nodes started in previous Risk Review- Perform HAZOP, FMEA, What-if for nodes not covered in previous Risk Review (due to previous missing info)- Begin Human Factors and Facility Siting checklist- Perform general Utility Failure checklist- LOPA of 1-5% of the scenarios: determine SIL, as necessary

Process Safety Development Phases in Major Projects

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Project Phase

Risk Review Phase Name Goals of Risk Review Risk Review Methodology

6 Commissioning

Conduct full hazard / risk review of operating procedures to control risk of errors during start-up, shutdown & other non-routine modes of operationClose out previous Risk Review issues (from earlier phases of project) and complete human factors and facility siting checklistThis Risk Review creates "Initial PHA" of the process

- HAZOP (2 guideword or 8 guideword) or What-if (no guideword) of operating procedures (choose method based on hazard & complexity of each task)- Complete HAZOP, FMEA or What-if for nodes started in previous risk reviews- Perform HAZOP, FMEA, What-if for nodes not covered in previous risk reviews (due to previously missing info)- LOPA of 1-5% of the scenarios; determine SIL, as necessary- Complete Human Factor and Facility Siting checklist

7 Post-Start-up

Conducted after 3-6 months after start-up similar to the future Revalidation, but with the goal of compensating for weaknesses in MOC process at the initial start-up of the new unit / process

- Audit of MOCs (and P&IDs and SOPS) since "Initial PHA" to ensure noting has been missed by MOC- HAZOP or What-if of missed or poorly reviewed changes- Update PHA for the entire set of changes (looking at a whole picture for the effect of all changes)- Close any pending recommendations (if possible)

Process Safety Development Phases in Major Projects

DO IT

1. Define critical behaviours to improve,

2. Observe target behaviours during a baseline phase to set specific goals

for achievement,

3. Intervene to change the target behaviours in the desired direction, and

4. Test the impact of the intervention by continuing to observe the target

behaviors.

Consider the power of rewarding safety feedback to increase safe work

practices. Praising people for safe work practices:

1. Increases the probability that these work practices will be performed

safely in the future,

2. Builds a more open and positive safety culture

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Managers Role to Improve Safety Culture1. Safety rules are consistently and fairly enforced.

2. Suitable personal protective equipment (e.g., safety glasses, harnesses) is

readily available to employees.

3. Work schedules don’t compromise employees’ safety (e.g., excessive

overtime, unrealistic production pressure).

4. Management spends sufficient time on the floor interacting with

employees.

– This increases employee input for safety.

– This shows employees that “management cares”.

5. Employees are actively involved in managing safety efforts.

6. Safety management systems (e.g., training, discipline) are in place and effective.

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Backup for Challenges in Construction slide

Properties :

Dynamic in Nature

Frequent work team rotations,

Exposure to changing weather conditions,

High proportions of unskilled and temporary workers.

The safety record of the construction industry is very bad w.r.t. other

industries due to

Complexity of the work or system,

Risk nature of works,

Management commitment and way of working,

Safety knowledge and commitment at individual level

Personal behaviour

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Proactive Safety Measure Tools Target TimelinesImparting Pre-employment & job specific training 100% Implemented & Ongoing

Compliance to Work Permit System 100% Implemented & Ongoing

Safety Communications:Mass MeetingJob specific hazards communication thru PEP talk

- Monthly per site- Daily at the start of the shift

Implemented & Ongoing

Visual SOPs in local language 2 per AIC MonthlyPromoting culture for Near Miss incidence reporting As & When happens On-goingJob Cycle Checks 1 per officer MonthlySafety Observation visits by TSL employees 3 per officer Monthly

Contractor Safety Audits for identifying severity 4 & 5 observations and corrections by:- Contractor Supervisors- AIC / SIC- Safety Professionals

- Daily- Twice a week- Thrice a week

On-going

Incident InvestigationAs & When required

On-goingPre Start up Safety Review for all critical equipments FY14

Targets : Lead Indicators

Lime Plant 600 tpd x 2 nos: 0.4

mtpa600 tpd x 3 nos: 0.6

mtpa

Lime Plant 600 tpd x 2 nos: 0.4

mtpa600 tpd x 3 nos: 0.6

mtpa

Blast Furnace4300 m3 x 1 no: 3.2 mtpa4300 m3 x 2 nos: 6.4 mtpa

Blast Furnace4300 m3 x 1 no: 3.2 mtpa4300 m3 x 2 nos: 6.4 mtpa

Sinter Plant496 m2 x 1 no : 5.75 mtpaPellet Plant : 5.0 mtpa

Sinter Plant496 m2 x 1 no : 5.75 mtpaPellet Plant : 5.0 mtpa

Stamp Charged Coke Ovens

1.5 mtpa3.0 mtpa

Stamp Charged Coke Ovens

1.5 mtpa3.0 mtpa

Converter310 t x 2 nos: 3.1 mtpa310 t x 3 nos : 6.2 mtpa

Converter310 t x 2 nos: 3.1 mtpa310 t x 3 nos : 6.2 mtpa

Slab Caster2 strand x 1 nos: 3.00 mtpa2 strand x 2 nos: 6.00 mtpa

Slab Caster2 strand x 1 nos: 3.00 mtpa2 strand x 2 nos: 6.00 mtpa

Hot Strip Mill2000 X 25 mm: 3.5

mtpa2000 x 25 mm : 5.5

mtpa

Hot Strip Mill2000 X 25 mm: 3.5

mtpa2000 x 25 mm : 5.5

mtpa

UnitPhase – 1 (Comm : 2013)Phase – 2 (Comm : 2015)

UnitPhase – 1 (Comm : 2013)Phase – 2 (Comm : 2015)

Cold Rolling Mill1870 X 0.3 mm: 2.2

mtpa

‘The only proven way of achieving Excellence in Safety Management’

• Felt Leadership: Developing culture to accept Safety as personal responsibility for themselves and those reporting to them

• Accountability of line managers for the Safety Performance in their area of responsibility

• Safety information sharing during daily safety meetings, Mass meetings, AIC & SIC meetings

• Visible in area of work through frequent safety site visits for observations (safety contacts) and Contractor Safety Audits

Line Management Accountability & Responsibility:

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• Providing training on Contractor Safety Audits to contractor’s Supervisors. Support and hand-holding by TSL Project Managers & Safety Professionals

• Daily Audits by site supervisors of Contractors & Consultants, Weekly Site Audits by AIC / SIC members & twice a week audits by TSL safety professionals for identification and immediate correction of severity 4 & 5 observations

• Managing Contractors’ Safety performance in accordance to the same safety standards and procedures as with our own employees

• Clarity on Safety expectations wrt Tata Steel Standards & Procedures & procedures to all Contractor owners thru Contract Terms

Construction & Contractor Safety Management

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• Formation of PSRM Safety Subcommittee team & Training on PSRM to bridge knowledge gap

• Plant and Equipment from Technological Leaders having in-built safety features (Examples: HAZOP approvals for all designs prior to manufacturing & supply, Covers for all cast house runners, in-built lockable positive isolation features in all electrical panels)

• Incorporation of specific Safety features in design of plant & equipment based on past learning (Examples: automatic drill bar changer for all tap holes in Blast Furnace cast house, enclosed type goggle valves for gas lines for elimination of gas exposure & positive isolation using hydraulic locking for cast house machines)

• Ensuring adequacy checks of safety features at design stage using PSRM. Quantity Risk Analysis in High Hazard Operations viz. Gas holder, BF Bleeder etc.

Process Safety Risk Management

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• Deployment of TSL Safety Standards with focus on phase-wise activities involved

• Safe Work Procedures for all the jobs & activities

• Safe Operating Procedures in local language for day specific work, hazards associated and mitigation measures

• Job Cycle Checks by TSL employees to bridge gap in deployment of SWP

• Shift-wise / Daily / Weekly / Monthly verification of compliance of ‘physical conditions’ of critical Standards (Excavation, Gas Cutting & welding sets, material handling Checks on

• Task-based Risk Assessments for the high hazard / more critical tasks

Procedures & Performance Standards

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My Life is My Life:

•Positive Isolation Safety Subcommittee is working on following :

a)Energy Source Identification (Establish and approve procedure for Isolation points, Method of isolation & The locking points)

b)Accreditation / Authorization for Isolating Persons

•Formulation of Isolation Procedure for the Complex Isolation and Energy Source Identification document

•Deployment of equipment isolation using Personal Locks & System Locks thru contractors is at early stages

•Implementation of Methods of Isolation (i.e. Control Stop, Individual, Group & isolation for working alone)

Positive Isolation

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Working on Safety Management System that includes two types of audits:

• Behavioral Audits - to assess people and their conduct (Focuses on identifying, disclosing and eliminating deviations resulting from improper, inappropriate and/or unsafe behavior and conduct)

• Managerial Audits - to assess the management system in terms of its appropriateness and compliance (Assess levels of efficiency of the Process Risk and safety management system)

● Effective use of 6-Step Safety Observation technique with focus on behavior change thru Safety Contacts (identification of risks and mitigation measures)

● Rewards for Positive behavior & Consequence for repetitive negative behavior

Safety Observation & Audit Process

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• Proactive implementation of learning from incidences at Jsr / other sites by parallel deployment of key relevant recommendations

• Addressing root causes thru Engineering Solutions / safeguards in Design Stage

• Reporting & timely investigation of all incidents (tendency to hide & difficulty due to skewed ratio of workmen to supervisors)

• Promoting timely reporting of Near Misses by reward & recognition (for contract employees)

● Class room training on Incident Investigation for new recruits, project managers of contractors

Incident Investigation

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Road Safety - Major area of concern during Construction Phase

Physical:• Uneven approach, narrow & loose soil (non-compact) roads• Major excavation work and land filling activities : Heavy movement of

earth moving equipments • Outsourcing of dumpers by major contractors to multiple sub-contractors• Non-uniform illumination at construction sites• Incomplete periphery fencing / boundary wall• Pre-employment training facilities inside site

Human:• Deployment of non-educated drivers and helpers• Overtime working by drivers• Intoxication habits of local people• Delay in implementation of Gate Pass System

Road & Rail Safety

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Actions taken and In-process / Proposed:

• Heavy vehicle audits by CFT as per checklist• Detailed mapping of roads for material movement• Implementation of One way traffic & display of sign boards• Deployment of Road Safety commandos on junctions• Road Safety awareness Campaigns and posters• Site-wise assigned parking place for heavy vehicles

• Focus on constructing roads at site on priority before monsoon• Separate route for entry and exit of light & heavy vehicles• Restricted / No entry for two & three wheelers inside plant• Monitoring of driving habits through electronic technology• Driving permits to be revoked before violations become collisions• Defensive driver training for issuing permit to drive at site• Proactive implementation of learning on Rail Safety from Jamshedpur

Rail & Road Safety

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Actions taken and In-process / Proposed:

• Provision of Rest rooms and drinking water at each site

• Installation of First aid Boxes, 1 First Aid Centre and 3 First Aid outposts

• Procurement of Critical Care Ambulance

• Creating pool of trained and certified First Aiders

• Recruitment of Doctors and paramedical staff in process

• Maximize Solid Waste Utilization

• Green Belt Development

• Labour Colony – Health & Hygiene Issues

• Recycling of bio-waste

Occupational Health and Environment

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•Leadership training with a focus on the behavioral aspects of safety for all external recruits

•Pre-employment Safety training / induction by external agency (NTTF) to all categories of workers and re-training every six months

● Contractor Safety Audit training to Contractor’s Senior Management to Site Supervisor level and weekly monitoring of audit compliance

● Monthly Safety Newsletter in Local language to connect with family

● Plan to conduct:● Theme based safety awareness training on monthly basis thru

visual SOPs / Models, Do’s & Don’t in Safety Excellence Center (Infrastructure & facilities creation under progress)

● Contractor Orientation training for Sub-contractors

Training & Communication

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“Motivation”: The most important task and frequently the most difficult:

•‘Walk the Talk’ and demonstration of passion for Safety at all levels

•Constant communication on ‘Importance of Safe behavior’

•Involving maximum possible employees in Safety initiatives

•Timely addressing Safety concerns raised by employees

•Acknowledging and appreciating safe act / behavior

•Internal competition by recognizing Safe workplace

•Consequence Management : Safety is the precondition of employment

Consequence Management & Motivation:

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Created by: OS0059 Date: 8/13/2010Doc. Classification: Public

Fool proof: Following or executing such a plan that will eliminate the root cause. So that even a fool will not be able to commit mistakes. This can be done by providing mechanization or automation

Fail Safe: Planning in such a way that even if the situation arises, the effect will be zero for e.g. a person may fall from height in case he stumbles, but will be safe if he wears safety belt

Fail Soft: Planning is done in such a way that even if situation arises, the effect can be minimized for e.g. A person may fall while driving two wheeler, but will be hurt less if he is wearing helmet

Commonly used fool proof

3 pin plug

Commonly used Fail SafeAll Electrical/Electronics connectors.

Documents

1 “ Safety in Construction ” Prakash Nirwan 28 th June’12, Hotel New Marrion, Bhubaneshwar SAFE KONNECT 2012 “Moving ahead in Industrial Safety” Confederation