HANDBOOK FOR OCCUPATIONAL HEALTH & SAFETY …about.puma.com/damfiles/default/sustainability/standar… · · 2014-09-119.13.1 Fire and Safety Precautions ... 13.4.3 Dry Ice

HANDBOOK FOR OCCUPATIONAL HEALTH & SAFETY

2013

HANDBOOK FOR OCCUPATIONAL HEALTH & SAFETY 04-2012

Foreword

At PUMA, we believe that our position as the creative leader in Sportlifestyle gives us the opportunity and the responsibility to contribute to a better world for the generations to come. A better world in our vision — the PUMAVision — would be safer, more peaceful, and more creative than the world we know today. We believe that by staying true to our values, inspiring the passion and talent of our people, working in sustainable, innovative ways, and doing our best to be Fair, Honest, Positive, and Creative, we will keep on making the products our customers love, and at the same time bring that vision of a better world a little closer every day. At PUMA, we aim to bring our trading practices in line with the principles of sustainable development. We strive to meet the requirements of the modern day without compromising the possibilities open to future generations. This means that we do not just want to provide high-quality products, but it prompts us to ensure that these products are manufactured in decent workplaces where human rights are respected and environmentally-friendly conditions are maintained. PUMA takes on its responsibility for everybody involved in this production process, whether a PUMA employee or not. The Guiding Principles on Business and Human Rights developed by John Ruggie that have been adopted by the UN as the “Protect, Respect, Remedy” Framework requires a pro-active approach that looks at the impact that our products and business have in the markets where we operate. This responsibility cannot replace nor substitute the responsibility of our production partners within their own manufacturing facilities. Our Code of Conduct expresses the expectations we have of our production partners. The PUMA.Safe Handbooks for Social, Occupational Health & Safety, Product Safety and Environmental Standards elaborate in detail the practical criteria and steps required to implement this Code. These guidelines do not necessarily represent the national laws of countries where goods are manufactured, but rather our proactive approach to protect, respect and remedy health & safety issues in our supply chain. In these Handbooks, we clarify where our standards may exceed local requirements based on international standards and trends and what we expect specific types of partners to meet. These handbooks are subject to continuous and periodic updates, so suggestions and comments to improve these handbooks are welcome. By following these requirements and recommendations, our partners share our vision for a better world which they help make real and palpable for thousands of workers and communities. PUMA takes this partnership of shared responsibility seriously. We reserve the right to terminate business relations when a partner disrespects and seriously violates the letter and spirit of our Code and policies.

Shirley Justice GM of Global Sourcing

Dr. Reiner Hengstmann Global Head Social & Environmental Affairs


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Table of Contents

1 Introduction/How to Use this Handbook .......................................................... 7

2 PUMA Occupational Health and Safety Policy ................................................... 8

3 A Note on Human Error .................................................................................. 8

4 Glossary of terms ........................................................................................ 10

5 Management systems .................................................................................. 10

5.1 OHS policy statement ............................................................................. 12

5.2 Plan (Planning) ...................................................................................... 12

5.2.1 Hazard identification and risk assessment .......................................... 12

5.2.2 OHS objectives ................................................................................ 15

5.3 Do (Implementation and operation) ........................................................ 16

5.3.1 OHS programs ................................................................................. 16

5.3.2 Resource, roles, responsibility ........................................................... 16

5.3.3 Competence, training and awareness ................................................ 16

5.3.4 Communication ................................................................................ 17

5.3.5 Documentations ............................................................................... 17

5.3.6 Document Control ............................................................................ 17

5.3.7 Risk Management and Controls ......................................................... 18

5.4 Check (Checking and Corrective action) ................................................... 18

5.4.1 Monitoring and measurement ........................................................... 18

5.4.2 Evaluation of compliance, Corrective and Preventive Actions ............... 18

5.4.3 Control of records ............................................................................ 18

5.4.4 Internal audits / inspections ............................................................. 19

5.5 Act (Management review) ....................................................................... 19

6 Health and Safety Committee ....................................................................... 19

6.1 Objectives and functions ........................................................................ 19

6.2 Health and Safety Committee training ..................................................... 20

7 Emergency preparedness and response ........................................................ 20

7.1 Flood ..................................................................................................... 22

7.2 Riot and other incidents of mass hysteria ................................................ 22

7.3 Earthquake ............................................................................................ 23

7.4 Tornado ................................................................................................ 24

7.5 Typhoon ................................................................................................ 24

7.6 Tsunami ................................................................................................ 24

7.7 Landslides ............................................................................................. 26

8 Fire safety ................................................................................................... 26

8.1 Fire equipment. Provision and maintenance ............................................. 27

8.2 Internal safety teams ............................................................................. 28

8.3 Fire safety training ................................................................................. 29

8.4 Layout, equipment and communication ................................................... 29

8.4.1 Layout ............................................................................................. 30

8.4.2 Fire equipment installation ................................................................ 30

8.4.3 Fire safety signage ........................................................................... 30

9 Building and Architecture ............................................................................. 31

9.1 Purpose-built facilities ............................................................................ 31

9.2 Ground Investigation .............................................................................. 34


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9.2.1 Definitions ....................................................................................... 34

9.2.2 Programme of Works ....................................................................... 35

9.2.3 Form of Report ................................................................................ 35

9.2.4 Quality Assurance ............................................................................ 35

9.3 Earthworks ............................................................................................ 35

9.3.1 Definitions ....................................................................................... 35

9.3.2 Trench Safety .................................................................................. 35

9.4 Roadworks and Traffic Flow .................................................................... 36

9.4.1 General ........................................................................................... 36

9.4.2 Traffice Flow tips ............................................................................. 37

9.5 Concrete ................................................................................................ 37

9.5.1 Approved Products ........................................................................... 37

9.5.2 Approved Installers .......................................................................... 38

9.5.3 Field Quality Control ......................................................................... 38

9.5.4 Rejected materials ........................................................................... 38

9.6 Metal Works .......................................................................................... 38

9.6.1 Engineering Calculations ................................................................... 38

9.6.2 Test Reports .................................................................................... 38

9.6.3 Inspection and Production Testing Programs ..................................... 38

9.7 Masonry ................................................................................................ 38

9.7.1 General Requirements ...................................................................... 38

9.7.2 Storage of Materials ......................................................................... 39

9.8 Roofing ................................................................................................. 39

9.8.1 Definitions ....................................................................................... 39

9.8.2 General Requirements ...................................................................... 40

9.8.3 Storage of Materials ......................................................................... 41

9.8.4 Testing ............................................................................................ 41

9.9 Thermal Insulation and Ventilation .......................................................... 41

9.9.1 General ........................................................................................... 41

9.10 Plumbing Works .................................................................................. 41

9.10.1 Project Drawings ........................................................................... 41

9.11 Sewerage ........................................................................................... 42

9.11.1 Definitions .................................................................................... 42

9.11.2 Inspection and Testing .................................................................. 42

9.12 Drainage Works .................................................................................. 42

9.12.1 System Description ....................................................................... 42

9.12.2 Site Work ..................................................................................... 43

9.12.3 Fixing ........................................................................................... 43

9.12.4 Laboratory drainage systems ......................................................... 43

9.12.5 Access to drains ............................................................................ 43

9.12.6 Ventilating Pipes and Stack Vents .................................................. 43

9.13 Electrical Works .................................................................................. 44

9.13.1 Fire and Safety Precautions ........................................................... 44

9.13.2 Protection ..................................................................................... 44

9.13.3 Labels/Circuit Lists/Cable Identification .......................................... 44

9.14 Green Constructions ............................................................................ 44

9.15 Restricted/Banned Materials ................................................................ 48

9.15.1 Asbestos ...................................................................................... 48

9.15.2 Lead ............................................................................................ 50

9.15.3 Related industrial illnesses ............................................................. 50


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9.16 Safe Construction Practices .................................................................. 51

9.16.1 Scaffolding ................................................................................... 51

9.16.2 Aerial lifts, Cranes, rigging and overhead hazards ........................... 52

10 Electrical safety ......................................................................................... 53

11 Machinery/Plant safety .............................................................................. 54

11.1 Control of Hazardous Energy/Lock-Out Tag-Out .................................... 55

12 Chemical safety ......................................................................................... 57

12.1 Building blocks of chemical safety plan ................................................. 58

12.2 Globally Harmonized System of Classification and Labeling of Chemicals 63

12.2.1 Physical Hazards ........................................................................... 64

12.2.2 Health and Environmental Hazard .................................................. 64

12.2.3 Classification of Mixtures ............................................................... 65

12.3 Hazard communication ........................................................................ 65

12.3.1 GHS Label Elements ...................................................................... 65

12.3.2 GHS Label Format ......................................................................... 66

12.3.3 GHS Material Safety Data Sheet or Safety Data Sheet ..................... 67

13 Product Process ........................................................................................ 67

13.1 Potassium Permanganate .................................................................... 67

13.2 Ozone Generators ............................................................................... 68

13.3 Abrasive Blasting................................................................................. 69

13.4 Sandblasting substitutes ...................................................................... 70

13.4.1 Glass ............................................................................................ 70

13.4.2 Water ........................................................................................... 71

13.4.3 Dry Ice ......................................................................................... 71

13.5 Spraying ............................................................................................. 71

13.6 Screen Printing ................................................................................... 71

13.7 Handicraft and Hand Painting .............................................................. 72

13.8 Laser Engraving .................................................................................. 72

13.9 Confined space, Sanitation and conditions of welfare facilities ................ 73

13.10 General conditions and materials handling ............................................ 75

13.11 Drinking water .................................................................................... 76

13.12 Toilets ................................................................................................ 77

13.13 Canteens/Kitchen Facilities .................................................................. 77

13.14 Safety signs ........................................................................................ 78

13.14.1 Requirements for color, size and shape .......................................... 78

14 Extreme Temperatures .............................................................................. 83

15 Auxiliary facilities/Plant (boiler, generator, forklift, elevator, air compressors) 84

16 Ergonomics ............................................................................................... 85

16.1 Working with Elevation and Fall Hazards .............................................. 86

16.2 High Frequency Vibration .................................................................... 90

17 Industrial Ventilation ................................................................................. 91

17.1 General ventilation .............................................................................. 91

17.2 Dilution and local exhaust ventilation ................................................... 92

18 Personal Protective Equipment (PPE) .......................................................... 93

19 Occupational health practice ...................................................................... 94

19.1 Medical care and first aid ..................................................................... 94

19.2 Health surveillance .............................................................................. 96

19.3 Structure of a health surveillance program............................................ 96

19.3.1 Analysis and reporting the results .................................................. 97

19.3.2 Health surveillance records ............................................................ 97


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20 Accidents investigation at workplace .......................................................... 97

21 Workplace monitoring .............................................................................. 101

21.1 Limit of Substances Hazardous Exposure ............................................. 102

21.2 Limit of Noise Exposure ...................................................................... 102

22 Workplace Health Promotion ..................................................................... 103

22.1 Workplace Stress ............................................................................... 105

22.2 Nutrition ............................................................................................ 107

22.3 Other areas of workplace health promotion ......................................... 109

23 Reporting to PUMA ................................................................................... 109

23.1 Establishing Procedures to Report Accidents ........................................ 109

23.2 KPI Reporting .................................................................................... 114

24 Contact ................................................................................................... 115

25 ANNEX .................................................................................................... 116


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1 Introduction/How to Use this Handbook

Each year workplace accidents cause numerous injuries and deaths and bring substantial loss to businesses and companies around the world. The PUMA.Safe team has repeatedly observed and reported a large number of health and safety issues in the corrective action plans during PUMA.Safe audits in our supplier factories. Amongst others, these issues include:

• Lack of competent health and safety team • No health and safety management systems in place • Poor fire safety management and inadequate control of fire hazards • Dangerous electrical installation and connections • Inadequate chemical management and labeling • No provision of personal protective equipment • Inadequate health and safety training for workers • No accident report and investigation procedures

All these issues may cause serious accidents and injuries to workers and contractors. Good health and safety conditions at work not only reduce the accident rate and labor turnover, but also help to enhance the value of the company and bring more success to the business by promoting motivation of staff and minimized spending on accident related cost. PUMA.Safe is publishing this handbook to serve as a practical guide for directors, managers, health and safety professionals and employees’ representatives so that they can improve health and safety in their organization effectively. Our current work on True Profit and Loss accounts take into account our impacts across our whole value chain, reaching as far upstream as raw material suppliers which had previously been out of scope of our Code of Conduct. As the PUMA supply chain covers companies and economic entities which are diverse in industry, nature and size, not all aspects covered in this handbook might be applicable, while additional aspects might be more relevant for specialized companies. In its bid to be a more desirable sportlifestyle company, PUMA may acquire new businesses in new product categories. These new product types will have specific health & safety requirements that may not be covered by this version of the manual. PUMA.Safe will release relevant codes of practice when necessary, and these should be considered as addendum to this manual until such time that a new version can incorporate new issues. For any further questions or suggestions, please contact your manager or [email protected].


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2 PUMA Occupational Health and Safety Policy

PUMA provides all employees with safe and healthy workplaces and makes any necessary effort to avoid damage to employee’s health. Likewise PUMA employees are expected to support this OHS policy, as well as, follow all applicable laws and regulations related to health and safety. A safe workplace has a very high priority within PUMA. Bearing in mind that work accidents cause personal tragedy and financial loss for the company, our aim is to have zero accidents for our own operations as well as in the contracted supplier production facilities of our supply chain. Health and safety is a shared responsibility. It is the duty of each employee to immediately report to their manager any hazardous conditions, injuries, accidents or illnesses related to the workplace. PUMA encourages employees to play an active role in identifying hazards and to offer suggestions or ideas to improve health and safety. We recognize that it requires permanent efforts to keep a safe and healthy work environment and we are committed to continuously improving our performance. Occupational Health and Safety (OHS) Committees are set up to monitor health and safety conditions and prevent accidents before they happen. Where these committees are required by local law, the establishment, constitution and maintenance of such should conform or exceed local requirements as necessary. Management has specific responsibility for: • Providing a safe and healthy working environment for the employees in their department; • Proactively identifying and addressing hazards in a timely manner; • Making health and safety a top priority; • Regularly instructing their staff on OHS aspects and document these instructions. Management is supported by the OHS committees and OHS specialists such as OHS engineers and industrial medicine practitioners who carry out regular checks as deemed necessary to satisfy local law and where necessary exceed it to achieve the aim of having zero accidents or work-related illnesses. PUMA ensures that the OHS performance is monitored on a regular basis to document that our OHS Policy and procedures meet our needs.

3 A Note on Human Error

Human or worker error is not always the result of carelessness or negligence, but follows from normal human characteristics. The desire for extra speed, less

work and making tasks easier, are some of the leading reasons why injuries occur. Also, people naturally become bored and distracted with repetitious work, which may cause loss of concentration. Designers, manufacturers and


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employers should be aware of these factors in designing plant and developing safe work practices. Factors contributing to human error include, but are not limited to: • forgetfulness • vigilance • workers diligence to ‘get the job done’ or to ‘find a better way’ • capacity to understand information • ergonomics • psychological or cultural environment • habit • fatigue • level of training. Forgetfulness - After first observing a hazard, a person can soon forget about it, especially if being distracted, and not taking adequate measures to control any risks that might be associated with that hazard. Vital controls should be interlocked to ensure they can only be operated in the correct order or at appropriate times. Vigilance - refers to a worker’s ability to be alert to danger or problems during operation, and is a higher requirement than ‘staying awake’. It implies active interaction with and awareness of the work environment. Diligence - Workers are often keen to perform well in their work and have a strong desire to meet targets or deadlines. This may become problematic where productivity incentives or bonuses are offered that may encourage workers to cut corners, or to work more quickly but less safely. Workers may also display initiative in ‘trying to find a better way’ without duly considering the safety issues involved. Information handling capacity - Vital information can be overlooked if it is presented too quickly, or if it comes together with other information (information overload). If a person has to monitor more than one ‘channel’ of information at any one time, they should have a clear order of priority. Training that does not take into account information handling capacity is doomed to failure and goes against the spirit of the PUMA Code of Conduct. Ergonomics - Ergonomics is the study of human and machine interaction. Poor operator comfort (no attention to the location of stools, buttons etc) can contribute to losses of concentration and error. Psychological or cultural environment - A corporate culture of safety will reduce human error that occurs due to fear of failure (to meet timetables or deadlines or quality standards). Workers who are not affected by bullies or harassment will also be more attentive and productive. Taking into account work-life balance issues, harassment outside of the workplace is also a factor that must be considered. Habit - People can continue a habitual activity despite indications of danger. Clear labeling of controls and clear, simple warning notices can help. People also get used to a particular arrangement of controls. Use standardized controls as much as possible, and ensure that location of the controls is appropriate. The action used to


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operate a control should also be compatible with the effect on the plant, for example, switching a control towards the left moves material into the plant in the same direction. This element deserves particular attention when considering the purchase of replacement plant: especially if the new controls are reversed or located differently. Fatigue - Long hours of work or long periods without adequate breaks can lead to loss of concentration, slow reflexes and increased risk of error. Excessive heat, poor ventilation, lighting and shift work also contribute to fatigue and should be taken into account. Training - It should not be assumed that people already know or can informally learn about workplace safety. Training must be provided to workers on any required personal protective equipment, newly introduced equipment or modifications to existing plant. All persons who supervise, manage or operate plant should receive appropriate training and instruction for health and safety. Training should include safe operating procedures, and any precautions that may be needed to control the hazards of the plant they operate.

4 Glossary of terms

• A hazard is any source with potential to cause harm or damage at work.

• A risk is the likelihood that someone could be harmed if exposed to a hazard.

• A Person Conducting a Business or an Undertaking (PCBU) refers to

any person that may be present in the workplace/facility. These cover visitors

and subcontractors.

• The Safety Data Sheet (SDS), also known as the Material Safety Data

Sheet (MSDS) or the Chemical Safety Data Sheet (CSDS), is a document that

provides information on the properties of hazardous substances/chemicals and

how they affect health and safety in the workplace. For example it includes

information on the identity, health and physicochemical hazards, safe handling

and storage, emergency procedures and disposal considerations. An SDS is

an important tool for eliminating or minimizing the risks associated with the

use of hazardous chemicals in workplaces.

5 Management systems

While working under pressure, it is easy to look for quick fixes for the problems. An Occupational Health and Safety Management System (OHSMS) is a set of procedures and practices which can help to take control of the OHS program by using a consistent and systematic approach. Management systems can be internally or externally certified, according to the standard OHSAS 18001. The level and detail of


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the management systems used depends on the size and complexity of the organization covered. Generally, management systems follow a Plan- Do- Check -Act model and embody the principle of continuous improvement.

When an OHSMS is in place it is possible to:

• Control risks which may result in accidents; • Reduce costs involved in cutting down errors and the costs of correcting

them; • Comply with all legal obligations and therefore commit less or no offenses to

the regulation; • Communicate the factory’s active commitment to doing things right, improving

morale and relations with the workers, as well as public authorities and business partners;

• Fulfil PUMA.Safe standards on OHS and associated reporting of Key Performance Indicators.

OHS Plan – Do- Check- Act Cycle ACT Perform management reviews. Implement corrective and prevention actions. Keep updated.

PLAN

State the OSE Policy. Include legal requirements. Conduct risk assessments.

Set objective and goals.

CHECK Conduct internal controls to monitor and measure. Use external and internal Audits results. Manage KPIs.

DO

Implement the procedures. Communicate the policy.

Train employees. Conduct drills.

Provide material and PPE.

The OHSMS must include (at least) the following elements: • An OHS Policy which includes clear goals • An organizational structure with clear authorization to act on all health &

safety issues as necessary (OHS committee, OHS team with clear responsibilities, etc.)

• A risk assessment on occupational health and safety hazards and a corrective action plan to address issues found

• A program of implementation for various health & safety concerns • Communication and training of staff in OHS issues • Measurement of performance against established standards or regulations,

collection of KPIs (tracking and reporting) • Continuous improvement goals and practices


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Both management and employees have to be actively involved in the planning, practice and evaluation of the OHSMS. A strong commitment from the upper-management is needed to implement the system. The Health and Safety Committee (HSC) plays a very important role in the effective implementation of the OHSMS. It links the efforts of the safety representatives (e.g. industrial health practitioners, OHS expert) and employees in order to ensure a safe environment.

5.1 OHS policy statement

A written OHS policy helps to promote an effective OHSMS, giving the organization a clear direction to follow. A policy statement is the basis for the chosen plan of action; It should state the overall objectives and a commitment to improving performance; The OHS policy should be communicated to all staff, for example via display on notice boards. It should be signed by the top management of the organization.

5.2 Plan (Planning)

Planning involves various activities such as: 1. Vulnerability assessment – it is a dynamic on-going process of assessing

hazards and risks that could impact the workplace. 2. Planning – a process for generating clear goals and objectives which identifies

specific tasks and responsibilities for people in the organization in response to various risk and incident situations.

3. Institutional Framework – the coordination of people and organizations which avoids the creation of new structures for new types of issues, like expanding the scope of existing H&S committees to accommodate new risk types found.

5.2.1 Hazard identification and risk assessment

The risk assessment is an important tool to protect employees, and businesses in general, as reasonably as possible. It helps to focus on the risks with the highest potential to cause harm, so that the most important things are solved first. Normally the assessment follows these steps:

• Identification of the hazard (walking around the whole premises, listening to employees concerns, looking at the MSDS identifying existing problems in the accident and health records). Each hazard should be studied to determine its level of risk.

• Identification of who might be harmed and how. • Evaluation of the risk (% of workers exposed, frequency of exposure, degree

of harm likely to result) and existing preventive measures (what is already in place and what is missing to eliminate or control the risk).

As climate change events and unstable social conditions occur with greater frequency and intensity, it is important that external factors are included in the exercise of risk assessment to ensure that the factory can develop appropriate responses. Gravity of potential damages:

1. Low – Accident or disease without work stoppage 2. Medium – Accident or disease with work stoppage 3. Serious – Accident or disease leading to a permanent partial incapacity 4. Extreme – Fatal accident or disease


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Exposure frequency of the workers: 1. Rare or unlikely – Exposure about once per year 2. Possible - Exposure about once per month 3. Frequent - Exposure about once per week 4. Very frequent – Daily or permanent exposure

The priority of hazards can be determined following the next chart:

Gra

vity

of

dam

ages Extreme 4 PRIORITY 2

PRIORITY 1 Serious 3

PRIORITY 3

Medium 2 Low 1 1 2 3 4

Rare or unlikely

Possible Frequent Very

frequent

Frequency of exposure

Record the findings. Define the actions to be implemented according to the hazards’ priority, costs, and time required for its implementation (considering that preventive costs are lower than repair-cost). Please refer to the hierarchy of risk control chart below.

Highest

Least Lowest

Level 1

Eliminate the Hazards

Level 2 Substitute the Hazard with

something Safer Isolate the Hazard from People

Reduce the Risk through engineering controls

Level 3 Reduce exposure to the hazard

using administrative actions Use personal protective

equipment

Le

ve

l o

f h

ea

lth

an

d s

afe

ty p

rote

cti

on

Re

lia

bil

ity o

f co

ntr

ol

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res

Most


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Most national regulations require that hazards are managed in conformance to this hierarchy. Elimination of a hazard must be the first priority as it is the most effective control. If this is not reasonably practicable, risk must be minimized by working through the other alternatives in the hierarchy. Level 1 control measures The most effective control measure involves eliminating the hazard and associated risk. The best way to do this is by, firstly, not introducing the hazard into the workplace. For example, you can eliminate the risk of a fall from height by doing the work at ground level. Risk can also be eliminated by removing the hazard completely, for example, by removing trip hazards on the floor or disposing of unwanted chemicals. Eliminating hazards is often cheaper and more practical to achieve at the design or planning stage of a product, process or place used for work. In these early phases, there is greater scope to design out hazards or incorporate risk control measures that are compatible with the original design and functional requirements. For example, a noisy machine could be designed and built to produce as little noise as possible, which is more effective than providing workers with personal hearing protectors. It may not be possible to eliminate a hazard if doing so means that you cannot make the end product or deliver the service. If you cannot eliminate the hazard, then eliminate as many of the risks associated with the hazard as possible. Level 2 control measures If it is not reasonably practicable to eliminate the hazards and associated risks, risks should be minimized using one or more of the following approaches: Substitute the hazard with something safer - For instance, replace solvent-based paints with water-based ones. Isolate the hazard from people - This involves physically separating the source of harm from people by distance or using barriers. For instance, install guard rails around exposed edges and holes in floors; use remote control systems to operate machinery; store chemicals in a fume cabinet. Use engineering controls - An engineering control is a control measure that is physical in nature, including a mechanical device or process. For instance, use mechanical devices such as trolleys or hoists to move heavy loads; place guards around moving parts of machinery; install residual current devices (electrical safety switches); set work rates on a production line to reduce fatigue. Level 3 control measures These control measures do not control the hazard at the source. They rely on human behaviour and supervision, and used on their own, tend to be least effective in minimising risks. Two approaches to reduce risk in this way are:


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Use administrative controls - Administrative controls are work methods or procedures that are designed to minimise exposure to a hazard. For instance, develop procedures on how to operate machinery safely, limit exposure time to a hazardous task, and use signs to warn people of a hazard. Use personal protective equipment (PPE) - Note that PPE use is considered the least reliable and provides lowest levels of protection. PPE use is vulnerable to human error and should be considered the last resort. Reviewing the assessment and continuously update it (setting one fixed date for evaluation and updating with every new equipment, substances, job positions and procedures introduced). It is possible to formalize the results of the risk assessment in a chart like in the following example:

For additional guidance on risk assessment methodologies and tools that maybe useful for your specific needs, please refer to local health & safety authorities specializing in this area or refer to the section on international resources at the back of this manual.

5.2.2 OHS objectives

The objectives should be based on the analysis of the strengths and weaknesses of the current OHS practices/program. They should be clear and measurable within a

Working area: (Name of the analysed area) Date: XX / XX / XXXX Drafter: (Name – Function) Number of concerned employees: (Total number of employees exposed to the hazard)

Hazardous situations

Potential damages

Risk’s gravity

Risk’s exposure

frequency

Priority Existing

preventive

measures

Actions to implement

Name the activity / workplace / machine with potential to cause harm.

Describe which type of harm(s) could be caused.

Define in numeric terms from 1 to 4 as from step 3.



Describe which measures are already in place to protect the employee.

Which actions will be implemented to reduce / control the risk.

Sewing machine (single-stitch, overlock)

Puncture finger of machine operator

Medium 2

Frequent 3

Priority 2

Needle guards on sewing machines

Train workers; regularly monitor completeness of guards on machines

The risk assessment should be kept suitable and sufficient, not overcomplicated!


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defined timeframe. For example, reduction of accidents from one year to the next by 10% or increasing the percentage of trained workers in first aid from 5 to 10% in one year.

5.3 Do (Implementation and operation)

5.3.1 OHS programs

The OHS programs describe the steps you need to follow in the daily work to reach your objectives.

5.3.2 Resource, roles, responsibility

In order to ensure a successful implementation of the policy, there should be solid grounds to achieve it, for instance:

• The resources (such as financial or human) needed to carry out the OHS plan have to be provided (for example: training programs so that employees meet their responsibilities, a space for the HSC meetings, well-maintained machinery, etc.).

• The roles of management, HSC and all employees have to be clearly defined and assigned to ensure that the policy is integrated into all their activities.

• Each individual has the responsibility to carry out their own OHS duties (for example employees should keep working tools in good condition; supervisors must ensure that employees wear their PPE; safety representatives must advise employees about the hazards to which they are exposed; senior managers must provide employees with a safe workplace, enforcing the OHS policy).

• The OHS authorities (such as the facility’s doctor, OHS Committee, local safety inspector) are identified and their range of action is decided.

5.3.3 Competence, training and awareness

An efficient OHS policy has to be reflected in people’s daily work and this can only be achieved if they are provided with sufficient knowledge. Activities have to be coordinated to ensure the competence of all employees.

• Trainings should be scheduled on a regular basis and start with an initial training as part of the hiring of any new staff.

Here are some of the most common OHS program elements:

• Communication of the OHS policy and its clear OHS rules and procedures. • Principles for hazard prevention and control. • Training programs (fire fighting, medical and first aid, etc.). • Emergency procedures. • Workplace inspections. • Incident (and or accident) reporting and investigation. • Data collection and analysis/record keeping. • Monitoring and evaluation.


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• While some training subjects are of general interest (fire evacuation, first aid procedures), others should be tailored to the specific needs of the workplace (hazardous substances, machinery, etc.)

• Awareness should be diffused through all levels. Employees should know how they can be impacted and how they can impact other workers with the processes around and involving them.

• Competence is the sum of education, training and experience.

5.3.4 Communication

Information and Warning System – the coordinated system of gathering and disseminating health & safety information and early warning. The OHS policy and regulations have to be communicated to all employees and PCBUs. Where possible and based on the comprehensive risk assessment undertaken, the information and warning system can be extended beyond the workplace to include families of employees and other potentially vulnerable stakeholders. Responsibilities can be communicated, amongst others, through:

• Induction training; • Notice boards; • Procedures manuals; • Job descriptions; • The Health and Safety committee; etc.

Where the operations of the facility may have a safety or environmental impact to the local community, communications on safety impacts should be extended in conformance to requirements of local law or where such laws maybe absent or inadequate proactive communications is recommended.

5.3.5 Documentations

Documentation is created in order to record and demonstrate compliance with different legislation, regulations and internal procedures. Documents are generally required by authorities, auditors, business partners, etc. It is therefore important to use a document control.

5.3.6 Document Control

To maintain current and accurate documents for conformance with the standards of management systems, the following tasks must be addressed by the organization:

• The scope of the overall document control system needs to be defined; • There must be a document authorization or approval requirement; • The control system must maintain a revision tracking process; • The control system must be designed to ensure that the appropriate revisions

are available at the workstations where they are used; • Out of date or obsolete documents must be promptly removed from the

workstation locations; • Out of date documents that need to be archived for historical purposes need

to be stored in a separate location.


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The primary purpose of the document control system is to insure that only the current approved documents are used in the planning and operation of the management system.

5.3.7 Risk Management and Controls

The operations and activities which involve hazards should have specific controls in order to manage them and reduce the risks based on the hierarchy of risk control.

5.4 Check (Checking and Corrective action)

5.4.1 Monitoring and measurement

In order to ensure that the OHSMS is being followed, and therefore that all the possible benefits which it might bring are being exploited, it is necessary to establish procedures to monitor and measure the OHS performance through KPIs and evaluation of how well the processes, activities and equipment-functioning are working. Key Performance Indicators (KPIs) define and measure progress towards the objectives and goals. KPIs have to be relevant for the users and reflect the organization’s needs.

5.4.2 Evaluation of compliance, Corrective and Preventive Actions

It is necessary to establish suitable procedures to evaluate periodically the extent which the facility is complying with all legal and non-legal OHS requirements, with the objective to implement the necessary measures to correct and improve any non-compliance. Measuring the achievement of objectives includes carrying out inspections and checks to ensure that the procedures are implemented and that the controls operate correctly. The collection and analysis of the OHSMS’ shortcomings come from such documents as accidents and illnesses logs, property damage reports, labour authority inspection reports, compliance audit reports, etc. In order to prevent recurrences and improve the conditions, these documents must be seen as a useful tool.

5.4.3 Control of records

In order to evaluate the performance of the OHSMS it is necessary to keep an accurate control of the OHS records.

The following records should be available at all times as applicable: • OHS Risk Assessment • Accident Records • Inspection records by labor authority • Fire fighting equipment inspection records • Fire drill records • Noise level and air quality checks • Water potability test • First Aid Certificates, license of company doctor / nurse • Clinic and occupational health surveillance records • Training records • Safety Data Sheets of all hazardous substances used


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5.4.4 Internal audits / inspections

Establish an internal program so that the OHSMS performance will be subject to audits / inspections. The aim of the audits should be to examine if the OHS policy and procedures are being implemented and also to identify any hazards which have not been covered yet. People involved in the audit process should have enough OHS knowledge, auditing skills and be aware of the importance of reporting accurately. In case no person with sufficient OHS knowledge is available internally, this function should be carried out by an external contracted expert.

5.5 Act (Management review)

The review of the OHSMS should be carried out by examining data coming from monitoring checks and the (internal and external) audit results. It is important to assess the results of the management reviews and generate outputs of these reviews, which will be communicated to the workers. In this way everyone can be informed on how well the objectives have been met. The most important part of “Acting” is to implement the necessary corrective and preventive actions. Additionally, it is important to update the OHSMS as it develops and new elements are added, looking to continuously improve its effectiveness.

6 Health and Safety Committee

6.1 Objectives and functions

Safety Committees have the function of keeping control over the measures taken to ensure the safety and health of the employees at work. In carrying out this function, safety committees ought to establish agreed objectives or terms of reference. An objective should be the promotion of co-operation between employers and employees in initiating, developing and carrying out measures to ensure the safety and health of the employees at work. To ensure continuous improvement and permanent monitoring, a Health and Safety Committee should be founded in every factory and comprise of:

• Chairman (Managerial Level) • Members (Department/Section Heads, Workers representative, Health Officer

or Company Physician, Safety Officer) Where local regulations specify a specific composition of members, the prescribed composition would be considered a minimum requirement. Within the agreed basic objectives specific functions can be defined. These might include:

• The provision of a link with the Occupational Safety and Health Branch of the Labor Department. Secure the necessary health and safety permits and ensure that all relevant standards are complied with;


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• The safety officer shall conduct regular safety inspections and ensure that all hazards are eliminated/ controlled. Adequacy of safety and health communication and awareness building systems in the workplace;

• The study of accident and workplace illness statistics and trends, so that reports can be made to management on unsafe and unhealthy conditions and practices, together with recommendations for corrective action. Keep records of accidents and illnesses and relevant activities in the factory;

• Conduct regular meetings at least once every three months with recorded meeting minutes. Where the local requirement is less frequent than this, the Puma requirement applies;

• Develop training programs for all employees such as fire fighting, emergency evacuation, first aid and others;

• Organizing safety promotional activities such as safety competitions, exhibitions, film shows, safety incentive schemes and safety suggestions.

6.2 Health and Safety Committee training

Members of the health and safety committee will need training to enable them to carry out their role and responsibilities effectively. Such training may include:

• Health and safety basics • Hazardous materials • Hazard identification • Workplace inspection • Effective meeting • Problem solving • Refresher training

7 Emergency preparedness and response

It is necessary to be prepared for emergency situations that threaten and could impact the OHS conditions. The steps which are followed in case of emergency should be described in procedures which are written, communicated and tested (conducting drills, notifying fire-fighters, signalizing meeting points, evacuation routes, emergency doors, installing alarms, etc.). The efficiency of these procedures should be evaluated for continuous improvement. In most instances, particular geographical areas or communities that are predictably under threat from hazard can be identified. These may include traditionally flood prone areas or communities living near volcanoes. However, disasters, whether natural or man-made, are still unpredictable and hence, it is necessary to be prepared for any emergency situations that could threaten or impact the OHS conditions. Emergency Management is a strategic process, and not a tactical process. Below are some guidelines that should be observed during disasters or emergency situations that could occur in a facility. However, the efficiency of these procedures relies on a thorough integration of such guidelines and should be evaluated for continuous improvement.


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For every emergency situation it is a must to always:

• Listen to the TV or radio for information. • Secure the facility, close windows and secure outdoor objects or bring them

indoors. • Stockpile emergency building materials and ensure a supply of water for

drinking and sanitary purpose. • Limit using the phone, except for serious emergencies.

Planning for all forms of emergencies including disasters goes beyond the scope of OHS management systems that only look inwards towards its own employees. Disaster risk planning involves eight categories of planning activities:

1. Vulnerability assessment – it is a dynamic on-going process of assessing

hazards and risks that could impact the workplace.

2. Planning – a process for generating clear goals and objectives which identifies

specific tasks and responsibilities for people in the organization in disaster

emergencies.

3. Institutional Framework – the coordination of people and organizations which avoids the creation of new structures for disaster preparedness and instead works within established networks and systems, like existing H&S committees.

4. Information and Warning System – the coordinated system of gathering and disseminating vulnerability assessment and early warning. The warning system must be developed that will convey to all employees and affected stakeholders effective warnings without assuming that normally functioning communication systems will be available. In addition, any relevant stakeholders should be forewarned about hazards that might lead to appeals for assistance and this should include communications with family members of affected employees.

5. Resource base – anticipated disaster relief and recovery needs should be made explicit and specific arrangements and written agreements should be established in order to assure the provision of goods and services as maybe required. This includes equipments and materials needed.

6. Response Mechanisms – a vast number of disaster responses ought to be considered, incorporated into the overall emergency preparedness plan and communicated to the workplace that would coordinate and participate in those responses if a disaster occurred.

7. Education and Training – through a variety of education programs those who may be threatened by a disaster ought to learn what to expect and what they will be asked to do in times of disasters. Where possible, coordination with local authorities/stakeholders should be done in order to learn the problems and gaps that may exist in the workplace plan.

8. Rehearsals/Drills – provide opportunities to reemphasize training program instructions, identify gaps that may exist in the disaster response plan and inform on-going revisions of that plan. It may not be necessary to perform drills for all types of identified potential disasters as legal requirements usually only refer to fire safety, however, for purposes of thorough preparation, drills covering all identified hazards should be considered.


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What follows is a list of the natural and man-made disasters the incidences of which have been growing in frequency across the world due to various environment and socio-political pressures. A short description of responses has been included for each type, but for purposes of local applicability the specialized assistance of emergency organizations like the Red Cross/Crescent and the local authorities/experts should be consulted. Where there are local regulations for specific types of emergencies, these should be complied with.

7.1 Flood

• Learn about the community's emergency plans, warning signals, evacuation routes, and locations of emergency shelters.

• Plan and practice a flood evacuation route. • Be aware of stream, drainage channels, canyons and other areas known to

flood suddenly. If there is any possibility of a flash flood, move immediately to higher ground.

• Identify potential hazards through the regular risk assessment exercise and secure or protect them before the flood strikes.

• Be prepared to turn off electrical power when there is standing water, fallen power lines, or before your evacuation.

• Turn off gas and water supplies before you evacuate. • Secure structurally unstable building materials. • For drains, toilets, and other sewer connections, backflow valves or plugs

should be installed to prevent floodwaters from entering. • Turn off all utilities at the main power switch and close the main gas valve if

evacuation appears necessary. Do not touch electrical equipment if you are wet or standing in water.

• Never ignore an evacuation order. Do not walk through moving water. Use a stick to check the firmness of the ground.

• Monitor the radio, television or other information sources for weather updates.

7.2 Riot and other incidents of mass hysteria

• Be prepared for the worst; the unexpected can happen at any moment. Crowds are dangerous when they are in an ugly mood and normally placid people can turn frenzied just by being in the presence of other frenzied people.

• Remain calm. Riots bring intense emotions - strive to think rationally and pursue safety methodically. Avoid confrontation by keeping head down. Avoid attracting unwanted attention.

• Get inside safe spaces and stay inside. Typically riots occur in the streets or elsewhere outside. Being inside, especially in a large, sturdy structure, can be the best protection to hide from the mob. Keep doors and windows locked, avoid watching the riot from windows and balconies, and try to move inside rooms, where the danger of being hit by stones or bullets is minimized. Try to find at least two possible exits in case it is needed to evacuate the building. If rioters are targeting the building and gain entry, try to sneak out or hide.

• Stay on the sidelines. If caught up in a riot, do not take sides. Stay close to walls or other protective barriers if possible but try to avoid bottlenecks. These


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are areas where the crowd can be squashed into a tight place, such as tunnels, pillars, high fences and walls that go on for a long way.

• Assessment of crowding in passageways should be part of the regular risk assessment.

• If caught up in a car, stay calm. Remain inside the car unless the car becomes a focus for the riot, in which case it risks being torched, smashed or rolled over. Calmly and swiftly leave it behind and get to safety if that happens.

• Avoid being hit by riot control chemicals or weapons. Crowd control enforcers like the police may deploy riot control agents (tear gas, water cannons, rubber bullets, etc.) to disperse a crowd. These weapons and chemicals can cause severe pain, respiratory distress, and blindness. Try to stay away from the front lines of a riot, and learn to recognize the signs that a riot control agent has been used and how to handle exposure.

• Move away from the riot. The more time you spend in the midst of a riot, the greater the chance of being injured or killed. In most circumstances it is better to move out of a riot slowly.

• Get to a safe place, and stay put. Choose a safe haven carefully.

7.3 Earthquake

Surviving an earthquake and reducing its health impact requires preparation, planning and practice. Far in advance, gather emergency supplies, identify and reduce possible hazards, and practice what to do during and after an earthquake

• Ensure that there are earthquake plans for the building if site investigation

shows risk of earthquake. • Pick safe places in each room of the workplace. A safe place could be under a

piece of furniture or against an interior wall away from windows or tall furniture that could fall.

• If inside the building, stay inside until the shaking stops and it is safe to go outside. Do not run outside or to other rooms during shaking.

o Drop to the ground. o Cover head and neck (and entire body if possible) under a sturdy table

or other piece of furniture. o Hold on until the shaking stops. Be prepared to move with the shelter if

the shaking shifts it around.

• Do not stand and use a doorway. • Stay away from glass and hanging objects, or other large furniture that could

fall. • Do not use elevator. • If possible factories should have an evacuation area. • If outside, stay outside, and stay away from buildings utility wires, sinkholes,

and fuel and gas lines. Once in the open, get down low to avoid being knocked down by strong shaking and stay there until the shaking stops.


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7.4 Tornado

• Stay tuned for storm watches and warnings especially if there are

thunderstorms in the area. Listen for announcements of tornado watch and tornado warning.

• Learn about the tornado warning system of the country or locality. Most tornado-prone areas have a siren system. Know how to distinguish between the siren’s warnings for a tornado watch and a tornado warning.

• Have a tornado evacuation or emergency plan and drills. • Utility switches or valves should be turned off. • Go directly to an enclosed, windowless area in the center of the building that

is away from glass and on the lowest floor possible. Then, crouch down and cover the head. Interior stairwells are usually good places to take shelter.

• Do not use elevator to avoid being trapped once the power is lost. • Vehicles are extremely risky in a tornado. If the tornado is visible, far away,

and the traffic is light, drive out of its path by moving at right angles to the tornado. Seek shelter in a sturdy building, or underground if possible. If caught by extreme winds or flying debris, park the car as quickly and safely as possible out of the traffic lanes. Stay in the car with the seat belt on. Put head down below the windows; cover the head with hands and a blanket, coat, or other cushion if possible. Avoid seeking shelter under bridges, which can create deadly traffic hazards while offering little protection against flying debris.

• If outdoor seek shelter in a sturdy building. If not, lie flat and face-down on low ground, protecting the back of the head with arms. Get as far away from trees and cars.

7.5 Typhoon

• Pay close attention to the meteorological information by TV, radio or the internet. When a typhoon is close, do not go out in heavy rain. Suspension of work should at least coincide with local meteorological advice. However, commuting conditions often become unsafe during a typhoon and as such pro-active suspension maybe necessary depending on known and estimated road conditions that employees would need to take.

• When outside, watch out for falling roof tiles, signs, trees, etc, if possible bring helmet or anything to cover the head.

• When inside, watch out for broken glass. Stay away from windows during strong winds.

• Due to heavy rain, headwater may be swelled quickly. Do not get close to the river, etc. Stay away from flood prone area.

7.6 Tsunami

A tsunami is a series of destructive and very dangerous waves that result from earthquake activity or some other type of underwater disturbance (meteorite, landslide, underwater volcanic activity etc.).


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• Workplaces in a coastal region or near to the sea or at the sea level are prone for tsunami.

• Include tsunami evacuation as part of your evacuation plan and conduct practice drills once risk has been identified. Ensure that warning and evacuation signals are easy to understand.

• Assemble a safety pack that consists of food, water and a first aid kit. Keep it somewhere that is obvious and well-known to everyone in the building and easy to grab in an emergency.

• Heed natural warnings. Natural warnings can help to indicate the imminent arrival of a tsunami. Be aware that in many cases, these may be the only warnings you will get as safety authorities may not have a chance to get warnings and evacuation procedures implemented. Natural signs that herald the possibility of a coming tsunami include:

o An earthquake. If you are in a coastal zone, the occurrence of an earthquake should be immediate cause for alarm and evasive action.

o A rapid rise and fall in coastal waters. If the sea suddenly recedes (draws back), leaving bare sand, this is a major warning sign that tsunami may occur.

o Animal behavior changes. Watch for animals leaving the area or behaving abnormally, such as trying to seek human shelter or grouping together in ways they would not normally do.

• Heed community and government warnings. If the local authorities do have time to issue a warning, take heed. Take action. If a tsunami is likely to make landfall, react immediately. Put into place the Evacuation Plan. Actions should include:

o Move inland, and to high ground. Immediate movement away from the coast, lagoons or other bodies of water next to the coast is essential. This means going up to higher ground and even into hills or mountains. Always head away from the coast and keep moving inland.

o Climb high. If you cannot head inland because you are trapped, head up. Although not ideal, if this is your only option, choose a high, sturdy and solid building and climb up it. Go as high as you possibly can, even onto the roof.

o Climb a sturdy tree. As a very last resort, if trapped and unable to move inland or climb a high building, find a strong and tall tree and climb up it as high as possible. There is a risk of trees being dragged under by the tsunami, however, so this really is a measure to be used only if all other alternatives have been rendered useless.

• React quickly if caught up in the water. If you did not manage to evacuate but are caught up in the tsunami, grab onto something that floats.

• Keep away until the "all clear" signal is broadcast. A tsunami comes in waves. There may be many, many waves lasting for hours and the next wave may be even larger than the last.

• Try to get reliable information. Listen to the radio for updates on what is happening. Do not trust word of mouth.


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7.7 Landslides

If there is a possibility of a landslide in the area remember these guidelines: • During a severe storm, stay alert and awake. • Listen for unusual sounds that might indicate moving debris, such as trees

cracking or boulders knocking together. • Move away from the path of a landslide or debris flow as quickly as possible. • The danger from a mudflow increases near stream channels and with

prolonged heavy rains. Look upstream before crossing a bridge and do not cross the bridge if a mudflow is approaching. If near a stream or channel, alert for any sudden increase or decrease in water flow and notice whether the water changes from clear to muddy. Such changes may mean there is debris flow activity upstream, so be prepared to move quickly.

• Curl into a tight ball and protect the head if escape is not possible.

8 Fire safety

Fire is the most common type of emergency that can arise in a factory and can be a subject of major concern, if appropriate fire safety measures are not followed strictly. A fire safety management system, as detailed below, should be in place to ensure fire safety at all times. This is a simple template that can be adapted for other emergency situations for the facility.

STATUTORY COMPLIANCE and

APPROVALS

PERIODIC PREVENTIVE

MAINTENANCE

DOCUMENTATION OF MAINTENANCE

COMMUNICATION TEAM

FIRE FIGHTING

TEAM

EVACUATION TEAM

MEDICAL TEAM

STATUTORY COMPLIANCE WITH

RESPECT TO PERIODICITY

SCOPE and

DOCUMENTATION OF EVACUATION

DRILLS

FIRE SAFETY TRAINING

LAYOUT and EQUIPMENT STANDARDS

FIRE SAFETY

SIGNAGE

FIRE EQUIPMENT – PROVISION and MAINTENANCE

INTERNAL FIRE SAFETY TEAMS

EVACUATION DRILLS and TRAINING

LAYOUT, EQUIPMENT and

COMMUNICATION

FIRE SAFETY MANAGEMEN SYSTEM


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8.1 Fire equipment, provision and maintenance

Fire safety equipment must be provided in the factory in such numbers and types so as to fulfil legal requirements at the minimum. These include but are not limited to:

• Portable fire extinguishers o Adequate number and suitable type of portable fire extinguishers must

be provided in every section of the factory, based on the type of fire risk involved.

• Fire alarm calling points

o Electrically operated fire alarm system (battery backup should be provided).

o One or two fire alarm call-points need to be provided on every floor / section of the factory which should be installed along aisle/escape route or near exits.

o The wiring arrangement of the alarm system should be centralized per building as such that all the hooters are activated when any one of the call points is raised.

o Fire alarm system must raise a sound that is unique and distinct from lunch bell, bell raised to signify shift start or shift end.

• Fire hydrants, smoke detectors and automatic sprinkler system (if legally mandatory)

o Fire hydrant points of appropriate number (as specified by local law) need to be provided

o Smoke detectors and automatic sprinkler system needs to be provided (if mandatory by provisions of local law)

• Other fire fighting equipment (if legally mandatory)

o Sand and water buckets o Manila rope o Fire resistant helmets, gloves, boots and clothing o Fire Blankets

• Ancillary escape equipment – specialized escape equipment maybe needed

when fighting fires in specific conditions. It is important to assess if it is feasible and practical to invest in these equipment, such as harnesses or fire trucks, depending on the capacity of local fire fighting authorities. All specialized equipment need to be used only by fully trained and authorized personnel.

• Periodic preventive maintenance. All fire equipment must undergo regular preventive maintenance to ensure that they are in good working condition at all times. For this, the following must be noted:

• Preventive maintenance program should be in place. • Procedures, protocols and accountability of preventive maintenance, with

respect to fire equipment, must be clearly documented and communicated. • Maintenance checks need to be properly documented.


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8.2 Internal safety teams

Depending on the size of the factory, employees from every section of the factory should be organized into different teams to handle exiting during an emergency, as detailed below.

• Communication team Members of the communication team will be responsible for communicating the emergency to external bodies like fire brigade, calling for medical assistance, etc. The members of this team must be trained and informed about emergency numbers, content of communication calls, etc.

• Fire fighting team

Fire fighting team members will be the ones who will stop the fire, using available fire fighting equipment like extinguishers, fire buckets etc. Time is critical in any fire situation, so members of this team must be very well trained and be able to take fast decisions with confidence. Though there are cases where facilities have complete fire fighting equipment including fire trucks because local official fire fighting capacity is ill-equipped or too distant, it is not expected that the fire fighting teams would be solely responsible for putting out a major fire. Where the capacity of local fire fighting authorities maybe inadequate or help is delayed, it is crucial that fire fighting teams only fight the kind of fires they are equipped and trained to manage.

• Evacuation team

This team would primarily be responsible for smooth evacuation and would be trained in evacuation activities like aiding physically challenged, pregnant women, the elderly and persons with difficulties to evacuate. Occupants of welfare facilities on-site, such as children in crèches/day care should be given highest priority and therefore designated caretakers must be fully trained. They would also be responsible for ensuring that 100% of the people evacuate.

• Medical team

The medical team will be responsible for assessing the need for and providing first aid, as required.

It is crucial that all personnel, including subcontractors working in the facility, are aware that only authorized and trained personnel should be performing specific safety functions. It is crucial that the safety policy and procedures is immediately taught to all personnel including subcontractors on the first day of work. Good-intentioned employees that attempt to handle certain kinds of emergencies may put themselves and others in danger.

Evacuation drills Evacuation scenarios for all forms of emergencies as identified in the risk assessment, not just fire, should be included in all emergency drills. Evacuation drills and fire safety training need to be held periodically, following requirements of safety laws and regulations.


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Evacuation drills must be held at least as often as the safety and labor laws prescribe but will be held at least annually. Objectives of holding periodic evacuation drills are:

• To identify any weaknesses in the evacuation strategy; • To test the procedure after any recent changes in the factory layout, working

practices etc; • To familiarize new employees with evacuation procedures; • To identify weaknesses in emergency procedures and systems.

Evacuation drills would be conducted to cover all the sections of the factory. Wherever applicable, such drills shall be conducted separately at the dormitories during day time period and at night when workers are staying inside the rooms. Evacuation drills should be properly documented in the form of an evacuation drill log, providing all necessary information such as number of employees and visitors present, time taken for 100% evacuation, etc. The following should be kept in mind before a drill is conducted:

• Communicate details concerning the drill and inform people of their duty to participate. It may not be beneficial to have ‘surprise’ drills as the health and safety risks that may arise may outweigh the benefits. Ensure that this type of exercise is coordinated with the respective authorities;

• Ensure that emergency services (fire brigade etc) are aware they do not have to respond to the actions of the communication team. It would be beneficial if officials are present to observe the proceedings;

• Make sure that maintenance staff and / or service company representatives are available to restore services and plants (such as mains, boilers, generators etc).

8.3 Fire safety training

Fire safety training needs to be held periodically. It would include and is not restricted to the following content:

• Training on use of fire extinguishers and other related equipment, • Training on communication during fire emergencies, • Training on how to aid easy evacuation, • Training on providing specific first aid during fire emergencies, • Training on how to read evacuation route plans.

Specific physical and psychological requirements need to be taken into consideration when identifying employees for training. For example, an employee who is physically weak or mentally hesitant to fight fire should not be trained and retained in the fire fighting team.

8.4 Layout, equipment and communication

Following clauses on layout, fire equipment installation standards and fire safety communication need to be followed.


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8.4.1 Layout

• Fire exits o There must be at least two* exits on every floor, capable of clearing

the work area in a maximum of five (5) minutes. A 5 pound extinguisher can only fend off a fire source for a limited amount of time with increasing degree of ineffectiveness after the initial few seconds.

o An additional exit is required if travel distance is more than 25 meters in any direction.

o The width of every exit shall be equivalent to at least the width of the stairs and suitable to evacuate the building in a maximum of five minutes.

o Care needs to be taken to ensure that all exits are kept unobstructed (whether temporary or permanent) at all times.

* One exit will be considered sufficient for rooms where less than 30 people work. In particular, this also applies to floors which can be deemed to only have one room, for example open plan mezzanine floors.

• Fire exit doors o Shall open outwards and will not open into aisles and walkways o Shall have width equivalent to at least the width of the stairs o Must not be locked or obstructed under any circumstance when people

are inside the building • Aisles and corridors

o Main aisles should be clearly defined by yellow lines, continuous, unobstructed and leading to exits (unattended push carts, temporary workstations, cartons or piles of materials are considered to be obstructions).

o Primary aisle width shall not be less than 1.1 meters and secondary aisles shall be at least 0.8 meters.

• Stairways o Width should not be less than 1.1 meters o Stairs, platforms, landing and other parts shall be made of

incombustible material o Shall be clear of any obstruction o Shall lead directly to the street or any open space

8.4.2 Fire equipment installation

Fire equipment installation should be in compliance with the requirement of all applicable fire safety laws in terms of numbers, types and locations.

8.4.3 Fire safety signage

The following guidelines, on fire safety signage and related communication, must be followed. All signage and information on fire safety must be made out in the regional language as understood by majority of the workforce. Where a substantial number of workers present are not fluent in this language, all steps must be undertaken to ensure that all workers including subcontractors are trained. All signage and information provided must be readable from a distance and wherever necessary at


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standard eye-level. It is imperative that signage is not obstructed by any material from any reasonable distance where workers may be present in the room.

• Evacuation route plans o Should be visibly displayed at or near exits or passageways on every

floor o Maps should include: floor layout in terms of machinery / workstation

placement, location of fire equipment, first aid kits, exit and emergency exit points and arrows showing direction of the closest exit / emergency exit, as the case maybe.

o Size of map shall be sufficient to read from a distance of two meters. o Where it is neither feasible nor practical to have legible evacuation

maps posted in all sections of a facility (for example in large warehouse facilities), escape arrow markings or other indicators should be used.

• Signage

o Position marking (including pictures and words) with respect to all fire equipment need to be provided (on walls, red marks on pillars etc)

o Usage instructions need to be posted close to fire equipment o Information on precautions to be taken and protocols to be followed

during fire emergencies need to be posted in every major section of the factory.

o Phone numbers to be reached during fire emergencies will have to be displayed in every section of the factory.

o Under each extinguisher there should be a restriction box marked on the floor, so that no object is placed there and it stays free of obstructions at all times. The purpose of the restriction box should be explained to all workers.

9 Building and Architecture

9.1 Purpose-built facilities

Puma usually contracts out to suppliers that already have existing production facilities. However, depending on the nature of the business, facilities that are purpose-built for Puma production maybe agreed upon with contracted suppliers for use for a specific period of time. This would cover facilities expansion that is shared for production of non-Puma products as well as fully self-contained facilities exclusively for production of Puma-branded goods. It is expected that all local construction practices and requirements are to be fulfilled in order to receive building licenses and registrations. However not all local building requirements maybe in conformity with updated international construction/building standards and practices. This section serves as guidance for contract suppliers and their engagement with construction subcontractors. Where local standards are higher than international standards, the higher standard should apply.


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BUILDING, ARCHITECTURE AND OTHER RELATED STRUCTURES

This table will be used to assess the compliance of the building, warehouse, plant or of any other related structures with relevant standards. It is expected that all construction work must comply with required civil engineering/building licensing reporting requirements as indicated in the checklist below. Not all sections maybe relevant in terms of compliance with local law – as such this serves as guidance for discussions with building contractors.

Note: The succeeding terms and discussions will serve as a guide for Evaluation.

SAMPLE OF DOCUMENTS FOR INSPECTION

SECTION PERFORMANCE INDICATORS

OUTCOME

Ground Investigation

Program of Work Complete Schedule Monitoring (PERT-CPM) and Methodology Used

Soil Investigation Report Report Document

Quality Assurance of Report

Signed and Sealed by Geotechnical Engineer or equivalent

Earthworks Site Clearances Excavation Permit

Temporary Fencing Fencing Permit

Roadworks Site Clearances Excavation Permit

Temporary Fencing Fencing Permit

Concrete

Approved Products List of Accredited Suppliers

Quality Control Records of Procedure of Testing of Materials

Quality Assurance Records showing that a Civil Engineer/Material Engineer attest the correctness of report

Metalworks



Quality Assurance Records showing that a Civil Engineer/Material Engineer attest the


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correctness of report

Quality Assurance Engineering Calculations signed and sealed by a licence structural engineer or equivalent

Masonry



Roofing

Quality Assurance Approved roofing insulation must be installed

Quality Assurance Record of leak test conducted

Thermal Insulation

Quality Assurance Approved interior/exterior wall insulation must be installed as per plan.


Plumbing Works


Project Drawings and Schematic Diagrams

Complete set of plans duly signed and sealed by a sanitary engineer or equivalent


Quality Assurance Record of pressure test conducted

Quality Assurance Maintenance Record

Sewerage







Drainage

Works






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Electrical Works


Drawings and Schematic Diagrams

Complete set of plans duly signed and sealed by Electrical Engineer or equivalent

Safety Proper Labelling of related appurtenances

GREEN CONSTRUCTI

ONS

Program of Reducing the Amount of Energy Consumptions

Documents that proves the energy consumptions becomes less

Program of Reducing the Amount of Energy Emissions

Documents that proves the energy emissions becomes less

Program of Reducing the Amount of Water Consumptions

Documents that proves the water consumptions becomes less

Program of Reducing the Amount of Liquid and Solid Waste

Documents that proves the solid and liquid waste becomes less

The building was built from recycled materials.

Document that proves the claim

9.2 Ground Investigation

9.2.1 Definitions

Topsoil: the surface layer of earth that contains organic material and can also support vegetation.

Soil: earthen material not classified herein as topsoil or hard stratum.

Hard stratum: The words 'hard stratum' shall mean natural or artificial material, including rock, which cannot be penetrated except by the use of chiselling techniques, rotary drilling, blasting or powered breaking tools.

Fill: deposits or embankments which have been formed by persons, as distinct from geological agencies.

Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the purpose of ground investigation.

Boring: hole in earth, excavated by either percussion or auger equipment.

Drilling: any hole in rock excavated by rotary equipment.

Borehole: exploratory hole excavated by boring or drilling techniques.


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9.2.2 Programme of Works

The Contractor/Supplier shall prepare a programme of works for the investigation which will give a detailed schedule showing proposed time scales for all aspect of the work, details of all plant and equipment to be supplied with time schedules and a similar schedule for all the prepared personnel who will work on the project.

9.2.3 Form of Report

The report shall comprise of either a factual or interpretative or both types of reports as required by local law. Report formats and content requirements will vary depending on the local legal requirements; however the name of the Contract and the names of the Employer, Engineer and Contractor should be present. When legally required, the Contractor shall supply the calculations and analyses on which recommendations are based.

9.2.4 Quality Assurance

The work shall be carried out in accordance with the relevant Standards specific for each country of Project Implementation.

Where specifically designated, all work shall be carried out in accordance with a quality management system established in accordance with specific local or international Codes. There should be records to indicate compliance.

The Contractor’s geotechnical and environmental personnel employed on the Contract shall be competent to undertake the work required.

All drillers employed on the Contract shall be experienced and competent in percussion or auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent drilling supervisor per site shall be permanently on the Site during borehole operations. Health and safety on-site relies greatly on the competence of personnel hired for the task.

9.3 Earthworks

9.3.1 Definitions

Trench excavation means excavation in all materials of whatever nature encountered for trenches into which pipes, ducts or cables are to be laid, or manholes, chambers and appurtenances constructed, and the term pipe shall mean pipe of all kinds and for whatever purposes.

9.3.2 Trench Safety

Each employee in a trench shall be protected from a cave-in by an adequate protective system. Some of the protective systems for trenches are:

1. Trench has been sloped or battered back to safe angle for stability

2. Cut to create stepped benched grades

3. Supported by a system made with posts, beams, shores or planking and

hydraulic jacks


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4. Supported by a trench box to protect workers in a trench.

5. Additionally, excavated or other materials must be at least 2 feet back from

the edge of a trench

6. Safe means of egress shall be provided within 25 feet of workers in a trench,

and equipment such as ladders are appropriately supported.

7. No occupant is allowed to enter any unsupported trenches.

8. Barriers should be erected to ensure that no persons or vehicles fall in.

9. Limit the distance which vehicles are allowed to approach a trench.

10. Materials, remains (rubble) and equipment should not be stored near the edge

of an excavation to minimize chances of collapse.

Also be aware of the following conditions that can affect the stability of the trench itself.

1. Location of traffic

2. Changes in weather conditions

3. Vibrations caused by machinery

4. Physical conditions of nearby structures

5. Surface or groundwater or water in trench

6. Overhead or underground utilities

Footings and foundations shall be of the appropriate type, of adequate size and capacity in order to safely sustain the superimposed loads under seismic or any external forces that may affect the safety or stability of the structure. It shall be the responsibility of the architect and/or engineer to adopt the type and design of the same in accordance with generally accepted principles and standards of engineering. Whenever or wherever there exists in the site of the construction an abrupt change in the ground levels or levels of the foundation such that instability of the soil could result, retaining walls shall be provided and such shall be of adequate design and type of construction in accordance with generally accepted standards and principles of engineering.

9.4 Roadworks and Traffic Flow

9.4.1 General

Survey marks must be determined to ensure that the improvements/ construction are not encroaching on existing public roadways or properties. Where such encroachments are found and resurveying is needed for both legal and safety purposes, this should be clearly indicated in all relevant reports.


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9.4.2 Traffice Flow tips

There must be a traffic flow plan for the whole work area that must be communicated to all workers and visitors to the site. Below are tips regarding work zone traffic safety:

• Work zones need traffic controls identified by signs, cones, barrels and

barriers.

• Drivers, employees on foot, and pedestrians must be able to see and

understand the proper routes.

• Traffic control devices, signals, and message boards instruct drivers to follow

paths away from where work is being done.

• Approved traffic control devices, including cones, barrels, barricades, and

posts are also used inside work zones.

• Work Zone Protections: Various concrete, water, sand, collapsible barriers,

crash cushions, and truck-mounted attenuators can help limit motorist

intrusions into construction work zones.

• Flagging: Flaggers should wear high visibility clothing with a fluorescent

background and made of retro reflective material. This makes employees

visible for at least 1,000 feet in any direction. Check the label or packaging to

ensure that the garments are of the performance class required by local law

or at least performance level 2 where no local law exists. Drivers should be

warned with signs that there will be flaggers ahead. Flaggers should use

STOP SLOW paddles, paddles with lights, or flags (only in emergencies).

• Training: Flaggers must be trained certified and use authorized signaling

methods.

• Driving: Seat belts and rollover protection should be used on equipment and

vehicles as the manufacturer recommends.

• Where possible, only one-way traffic is allowed to minimize accidents. Where

this is not possible, trained bank men should be there to help guide vehicles in

the process of reversing direction.

9.5 Concrete

9.5.1 Approved Products

Specific contract documentation may identify approved products and approved or prequalified manufacturers and suppliers of products used in concrete work. Health and safety on any concrete structures primarily relies on the integrity of the quality of concrete used during the construction. Concrete quality greatly influences the strength of the building. There must be record to show that all materials and workmanship were implemented during the construction. The strength of the foundations, columns, beams and floor system made by concrete must be of acceptable quality. The quality must be defined by the attestation of a legitimate professional.


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9.5.2 Approved Installers

Contract specific documentation may identify approved or prequalified providers of concrete construction services.

9.5.3 Field Quality Control

The Contractor must carry out the test procedures required by this section and any other tests and test procedures as directed by the Engineer in the duration of the construction of the building/warehouse/plant. The test procedures are to be carried out using the facilities of an approved independent testing laboratory.

9.5.4 Rejected materials

Any material rejected by the Engineer during the construction, in particular cement which has deteriorated or aggregates which have segregated or become contaminated must be recorded in the minutes or journal of construction of the structure. All rejected materials must be appropriately stored and disposed.

9.6 Metal Works

9.6.1 Engineering Calculations

A complete set of records with engineering calculations and shop drawing as directed in the Project Documentation should be available. All engineering calculations are to bear the stamp of a professional engineer. Health and safety on any metal/steel structures primarily relies on the integrity of the quality of steel used during the construction. There must be a record to show that all materials and workmanship implemented during the construction were according to specifications. The strength of the foundations, columns, beams and floor system made by steel and metal must be of acceptable quality. The quality must be defined by the attestation of legitimate professional.

9.6.2 Test Reports

The Contractor of the facilities must submit test reports and attested by qualified professionals bearing their stamp.

9.6.3 Inspection and Production Testing Programs

The Contractor of the facilities must submit to the Project Engineer a detailed description of inspection and production testing programmes and inspection reports for all types of coating of aluminium or aluminium alloy.

9.7 Masonry

9.7.1 General Requirements

Samples of each type of masonry unit used must be approved by the Engineer before use. All subsequent units are to be up to the standard of the approved samples. There should be a submitted record of approval.


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Health and safety on any masonry structures primarily relies on the integrity of the quality of masonry used during the construction. Masonry quality greatly influences the strength of the building. There must be record to show that all materials and workmanship were implemented during the construction. The strength of the wall system made by masonry materials must be of acceptable quality. The quality must be defined by the attestation of legitimate professional.

9.7.2 Storage of Materials

Masonry units delivered to the site are to be carefully unloaded and handled so as to prevent chipping and breakage. Tipping of units will not be allowed as this is both an unsafe practice as well as damages the units. The units are to be stacked on a level area in an orderly manner on planks or other suitable supports to ensure that they are free from contact with the ground. Stored units shall be kept under waterproof covers.

9.8 Roofing

9.8.1 Definitions

BASE SHEET is one layer of felt or combination sheet secured to the deck over which may be applied additional felts, a cap sheet, organic or inorganic fibre shingles, smooth coating or mineral aggregate.

BUILT-UP ROOF COVERING is two or more layers of roofing consisting of a base sheet, felts and cap sheet, mineral aggregate, smooth coating or similar surfacing material

CAP SHEET is roofing made of organic or inorganic fibres, saturated and coated on both sides with a bituminous compound, surfaced with mineral granules, mica, talc, inorganic fibres or similar materials

CEMENTING is solidly mopped application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material

COMBINATION SHEET is a glass fibre felt integrally attached to kraft paper.

CORROSION-RESISTANT is any non-ferrous metal or any metal having an unbroken surfacing of non-ferrous metal, or steel with no less than 10 % chromium or with not less than 0.20 % copper

FELT, NONBITUMINOUS SATURATED is matted asbestos fibres with binder for use with wood shingle and wood shake assemblies

GLASS FIBER FELT is a glass fibre sheet coated on both sides with bituminous compound

INTERLAYMENT is a layer of felt or non-bituminous saturated asbestos felt not less than 450 mm wide, shingled between each course of roof covering

INTERLOCKING ROOFING TILES are individual units, typically of clay or concrete, possessing matching ribbed or interlocking vertical side joints that restrict lateral movement and water penetration


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METAL ROOFING is metal shingles or sheets for application on solid roof surfaces, and corrugated or otherwise shaped metal sheets or sections for application on solid roof surfaces or roof frame works

NON-NAILABLE DECK is any deck, which is incapable of retaining an approved fastener

PREPARED ROOFING is any manufactured or processed roofing material, other than untreated wood shingles and shakes, as distinguished from built-up coverings

SPOT CEMENTING is discontinuous application of asphalt, cold liquid asphalt compound, coal tar pitch or other approved cementing material

UNDERLAYMENT is one or more layers of felt or non-bituminous saturated asbestos felt over which the finish roofing is applied.

9.8.2 General Requirements

Roof Construction and Covering Roof Coverings. Roof coverings for all buildings should be either fire-retardant or ordinary depending upon the fire-resistive requirements of the particular Type of Construction. The use of combustible roof insulation shall be permitted in all Types of Construction provided it is covered with approved roof covering and applied directly.

Roof Trusses. All roofs shall be so framed and tied into the framework and supporting walls so as to form an integral part of the whole building. Roof trusses shall have all joints well fitted and shall have all tension members well tightened before any load is placed on the truss. Diagonal and sway bracing shall be used to brace all roof trusses. The allowable working stresses of materials in trusses shall conform to requirements set by local law or international standards whichever is applicable. The minimum net section of the members after framing shall be used in determining the strength on the truss at any point.

A record of journal of construction must reflect the installation of the roof, waterproofing and insulation system of all construction work and installations above roof level are completed. Particular care is to be taken to ensure:

a) all rainwater, plumbing, air-conditioning and ventilation duct outlets have

been fixed in position and are protected against blockage or accidental

damage.

b) supports to ductwork, pipework, cable trays and the like have been

installed

c) all kerbs to roof lights, access doors, plant and water tanks have been

installed

The surface of the roofing substructure is to be clean and dry, free from ridges or indentations, laid to falls as required and not contaminated with oil or other deleterious matter. Records must show that no waterproofing membrane was applied until the roofing substructure was inspected and approved by the Engineer.


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9.8.3 Storage of Materials

Polystyrene insulation boards are to be protected against prolonged exposure to sunlight. Blanket type insulation is to be protected from moisture.

9.8.4 Testing

On completion of application of new roof waterproofing material to an existing roof but before application of insulation and protection, the Contractor shall seal off all rainwater outlets and flood the roof to a depth of 25mm. After 48 hours, visual inspection of the roof shall be undertaken from inside the building in the presence of the Engineer's Representative to establish that there are no leaks in the structure. Visual inspection at elevated level should be avoided where possible. Any elevated work should comply with relevant safety regulations. The Contractor shall make up any loss of water during the test due to either evaporation or leakage. The Contractor shall be responsible for the locating and sealing of any leaks found. The test shall be repeated, at the Contractor's expense, until no leaks exist.

9.9 Thermal Insulation and Ventilation

9.9.1 General

Thermal Insulation In countries in which the outside temperature is above the normal temperature the human can withstand, a thermal insulation of acceptable type and procedures must be implemented. More detailed standards must be secured from the local regulation bodies for implementation before the operation of the plant. Ventilation Inlets: A fresh-air inlet from the exterior of the building is necessary and the source of which shall be remote from other outside vents. Outlets: Ventilation shall be provided by one or more mechanical exhaust systems which shall draw air from each arc lamp and from one or more points near the ceiling. Systems shall exhaust to outdoors either directly or through an incombustible vent that is used for no other purpose.

9.10 Plumbing Works

This section specifies the requirements for the construction and installation of all works associated with the supply, storage and distribution of potable water.

9.10.1 Project Drawings

For purposes of clearness and legibility, the Project Drawings are essentially diagrammatic but at the same time size and location of equipment are drawn to scale where possible.


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Records must show complete detail of installation in conformance with accepted standard practice and manufacturer’s recommendations.

9.11 Sewerage

This Section includes specifications for the construction and rehabilitation of sewerage, surface water drainage and treated sewage effluent pipelines, piping, pipeline appurtenances and sewage treatment plants.

9.11.1 Definitions

Surface water: Water that flows over, or rests on, the surface of buildings, other structures or the ground; the definition is extended to include groundwater.

Sewage: Contents of a sewer that does not solely convey surface water.

Treated sewage effluent (TSE): Effluent from a sewage treatment works following completion of treatment of sewage and disinfection of the treated sewage effluent to attain a water quality standard suitable for reuse for selected purposes.

9.11.2 Inspection and Testing

Records of Inspection procedures and tests must be carried out at the place of manufacture. Pipes and joints were hydrostatically tested. The performance of pipes was verified by the testing of random sample pipes in accordance with the type of inspection and batch size mentioned. The pipes were subject to rejection on account of non-compliance with the following:

a) failure to pass hydrostatic test

b) failure of the longitudinal concrete surfaces of joints to meet dimensional

tolerances fractures or cracks passing through the shell, except that a single

end crack that does not exceed the depth of the joint shall not be cause for

rejection; surface defects indicating honeycomb or open texture spalls and

insufficient cover to the reinforcement.

9.12 Drainage Works

This Section specifies the requirements for the construction and installation of drainage works for buildings.

9.12.1 System Description

Internal drainage systems shall comprise the minimum pipework necessary to carry away the discharges from sanitary appliances in buildings quickly and quietly. Drainage pipework installations shall be such that there is no leakage of contaminated water or foul air into the building.

Drainage systems, including materials, joints, supports and fixings shall be durable under the expected operating conditions.


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Pipework and fittings in drainage systems shall be installed so that defective parts can be replaced without undue difficulty.

9.12.2 Site Work

A record of check was made to ensure that all holes, chases and ducts required for pipework was properly provided in accordance with the relevant provisions.

Where several pipes pass through floors in close proximity, the Contractor must provide a single framed opening in lieu of individual sleeves. Framed openings must have the approval of the Engineer.

9.12.3 Fixing

Water supply and discharge pipes were installed before sanitary appliances are fixed. Before fixing an appliance into position, the Contractor must ensure that the discharge pipe is clear of obstruction. Joints between appliances and traps and/or pipes must be of the union or detachable type.

9.12.4 Laboratory drainage systems

The chemical resistance properties of pipes, fittings, jointing systems and any other drainage accessory shall be suitable for conveying all solutions expected to be discharged to the drainage system. Where possible, technical advisory services provided by manufacturers shall be used to ascertain the suitability of products to be used in the drainage system. A full list of the solutions expected to be discharged to the drainage system is given in the Project documentation.

Drainage systems for the collection of solutions which are not permitted to be discharged to existing drainage facilities shall be kept totally separate form other drainage systems.

Drainage systems to which grit, gravel, sand or other granular material shall be discharged shall have sufficient abrasion resistance properties and be fitted with suitable traps and catch basins.

9.12.5 Access to drains

Sufficient and suitable access was provided to enable all pipework to be tested and maintained effectively. Access covers, plugs or caps should be sited so as to facilitate the insertion of testing apparatus and the use of equipment for cleaning and/or for the removal of blockages. The use of apparatus or equipment should not be impeded by the structure or other services.

Access points should not be located where their use may give rise to nuisance or danger if spillage occurs.

9.12.6 Ventilating Pipes and Stack Vents

Ventilating pipes and stack vents must terminate with a domical cage or other cover that does not restrict air flow. They shall be positioned so that foul air does not cause a nuisance or health hazard.


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9.13 Electrical Works

9.13.1 Fire and Safety Precautions

Establish from Architectural Drawings where fire and smoke barriers exist, and make adequate provision of fire and smoke barriers in and around trunking, conduits, cables, etc., where they pass through floors and fire rated walls, and where protection systems are installed pack space between wiring and sleeve full with Fire Retardant Material and seal with caulking.

9.13.2 Protection

Records must show that the Contractor was responsible for his work and equipment until finally inspected, tested, accepted and handed over.

Protect work and material of other trades from damage that might be caused by his work or workmen and make good damage thus caused.

Protect exposed live equipment during construction for personnel safety.

Arrange for installation of temporary doors for room containing electrical distribution equipment. Keep these doors locked except when under direct supervision of an electrician.

9.13.3 Labels/Circuit Lists/Cable Identification

Proper labelling on the following must be very visible at all times:

a) substations, switchgears, switchboards, motor control centers and panels

b) Wiring Identification:

c) Conduit and Cable Identification

9.14 Green Constructions

Green Construction and Sustainability

Buildings, infrastructure and the environment are inextricably linked. Energy, water, materials and land are all consumed in the construction and operation of buildings and infrastructure. These built structures in turn become part of living environment, affecting living conditions, social well-being and health. It is important to explore environmentally and economically sound design and development techniques in order to design buildings and infrastructure that are sustainable, healthy and affordable, and encourage innovation in buildings and infrastructure systems and designs. The concept of sustainability in building and construction has evolved over many years. The initial concept was on how to deal with the issue of limited resources, especially energy, and on how to reduce impacts on the natural environment. Emphasis was placed on technical issues, such as materials, building components, construction technologies and energy related design concepts.


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Recently, non-technical issues became appreciated, such as economic, social sustainability and cultural heritage aspects of the built environment. Also, there is greater attention to creating more green buildings by upgrading the existing buildings through the application of new developments or the invention and use of innovative technologies for energy and material savings.

ENERGY

The energy consists of factors associated with energy demands of buildings, the efficiency of energy delivery and the use of fossil energy resources that results in harmful emissions and pollutions.

I. Impacts.

a. Climate Change

b. Fossil Fuel Depletion

c. Air Pollution

d. Human Comfort and Health

II. Mitigate Impact.

a. Designing the building to lower its energy demand.

b. Selecting efficient building systems.

c. Lowering the demand on non-renewable sources of energy.

d. Minimizing the amount of harmful substances produced by

the energy delivery system.

WATER

The water category consists of factors associated with water consumption and its associated burden on municipal supply and treatment systems.

I. Impacts.

a. Water Depletion

b. Increase of Liquid Waste

II. Mitigate Impact

a. Specifying efficient plumbing fixtures.

b. Creating a system for the collection and storage of rainwater.

c. On-site treatment of water.

d. Designing a landscaping plan that minimizes the need for

irrigation and watering.


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Construction Work/ Activity Specialized PPE Remarks

1 Work near unprotected Areas, such as but not limited to the following a. Working on scaffolds b. Working on roofs

Safety belt or harness Where there is a possibility of fall that will normally cause disabling injury

2 Work involving pouring of concrete, such as but not limited to the following a. Laying concrete slab b. Pouring of concrete for

beams and/ or columns

1. Safety chemical resistant boots

If worker’s feet may have contact with fresh concrete

2. Chemical resistant gloves

If workers hand may have contact with fresh concrete

3 Work involving laying of asphalt

1. Heat resistant gloves

2. Heat resistant safety footwear

If workers need to work on or near hot asphalt

4 Working with derricks and cranes

1. Color-coded vest with reflectorized

markings

Proper visibility and identification of critical persons, such as operators, riggers, signal men

2. Heavy leather gloves

For riggers

3. High visibility gloves

For signal men

5 Working with earth moving equipment

1. Heavy duty safety footwear

Safety shoes for relatively dry or sheltered work Water and mud resistant boots for wet outdoor works

2. Ear muff or ear plugs

When working near or on noisy equipment

6 Manual excavation or digging

Padded vest When work may involve being hit by falling materials

7 Work on top of or near bodies of water

1. Live vest 2. Safety belt

When there is danger of fall into deep water

8 Work where hot cutting and welding of metals are involved

1. Heat resistant light filtering face shield

2. Heat resistant and heat insulating gloves

3. Metal fume filtering

For welders and gas cutters


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respirators

4. Heat resistant protective clothing

5. Light filtering and heat resistant face goggles

For gas cutting and lieu of face shield

9 Work involving exposure to or handling of hot materials or work near open flames

1. Heat resistant and heat insulating gloves

For handling hit substances and materials

2. Heat insulating protective clothing

For working in hot working environment

3. Heat resistant face shield

For working near open flames

10 When working with live electricity above 50 volts AC or DC

1. Electrically insulated gloves

Electrical resistance must be suitable for the maximum electrical voltage of energized parts that may be handled by worker

2. Electrically insulated safety

shoes

3. Electrically insulated gloves

11 Work involving handling of noisy and or vibrating power tools and equipment

Vibration insulating gloves

Recommended total cumulative actual usage of tools shall be a maximum of 2 hours per day (for 8- hour work, duty cycle should be 1:4)

12 Work involving exposure to harmful dust

Dust filtering respirators If dust concentration is above recommended Threshold Limit Value (TLV) for the contaminant

13 Work that might involve shortage of oxygen

Self contained or supplied air respirator

Work in confined spaces or work involving depletion of oxygen supply

14 Working with organic solvent or toxic and/or corrosive chemicals

1. Chemical resistant gloves

If works involves handling of chemicals

2. Chemical filtering respirators

If a chemical emits vapors above recommended TLV for the contaminant chemicals

3. Chemical resistant face shield

If work may involve chemical splashes to the face

4. Chemical goggles If chemical vapors may


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irritate eyes 5. Chemical resistant

protective clothing If work may involve chemical splashes to the body of worker

15 Working with atmospheres containing contaminants above recommended threshold limit values for airborne contaminants

1. Appropriate containment filtering respirators

For atmospheres containing not more than ten times the recommended TLV

2. Containment protection for eyes

If contaminant irritate eyes

3. Self- contained or supplied air respirator

For environment containing more than ten times the recommended TLV

4. Chemical suits If contaminant may enter through skin

16 Working near vehicular traffic

1. PPEs with reflectorized or luminous markings for high

visibility

2. Heavy duty safety shoes

17 Work involves working under water

1. Self-contained or supplied air underwater breathing

apparatus

2. Thermal insulating wet suit

and accessories

If work involves long exposure to cold water

18 Working at night under low lighting conditions

1. High visibility gloves

For spotters

2. High visibility vest

For all workers within immediate vicinity of equipment

9.15 Restricted/Banned Materials

9.15.1 Asbestos

Asbestos is a set of six naturally occurring silicate minerals used commercially for their desirable physical properties. The prolonged inhalation of asbestos fibers can cause serious illnesses, including malignant lung cancer, and asbestosis (a type of


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pneumoconiosis). Long exposure to high concentrations of asbestos fibers is more likely to cause health problems. Asbestos is more common to be found in buildings and factories because of its sound absorption, average tensile strength, its resistance to fire, heat, electrical and chemical damage, and affordability. It was used in such applications as electrical insulation for hotplate wiring and in building insulation.

These are the following guidance that the PUMA.Safe required when dealing with asbestos:

• Management of asbestos and qualified person to:

o Train workers on how to handle asbestos and which kind of care they must take,

o Do inspections on the building areas to evaluate if the materials containing asbestos are in the right condition, and

o Create procedures and plans that ensure safety, clean-up and prevention of the release of asbestos into the air.

• Factories must keep under control all the areas that are known to have, or may have materials containing asbestos.

• Factories must follow laws and regulations related to asbestos. • Damaged materials that may contain asbestos must be sampled and tested to

determine whether they contain asbestos and what additional action is needed.

• Give trainings for maintenance workers to recognize materials that may contain asbestos.

• Mark the materials containing asbestos. Qualified person decides when it is not necessary to remove these materials and the factory must have a procedure to inspect periodically, to make sure these materials still do not pose a risk.

• When qualified person finds that the asbestos-containing material contains “friable” asbestos which means any asbestos-containing material that when dry, can be easily crumbled or pulverized to powder by hand, a qualified contractor must repair, enclose, or remove the material according to applicable laws and regulations.

• Replace materials that contain asbestos following all the health and safety requirements whenever is possible.

Since asbestos is one of the most hazardous chemicals that are commonly used for factories, here are some important implementation guidelines for asbestos:

• Factories should keep written records of the training. • A control of areas that are known to have, or may have, materials containing

asbestos should include the location, description, and condition of all materials containing asbestos;

• All areas of the factory building (e.g. mechanical areas, common areas, work areas, laundries, kitchen) should be inspected. Both friable and non-friable materials containing asbestos should be identified.


• Each year, the physical condition of any materials containing asbestos should be evaluated and any changes should be noted and included in the list referred to in the Training, Rules, and Record Keeping section.

• Factories should establish procedures to ensure that workers and work practices do not damage or disturb materials containing asbestos, which might release asbestos fibers into the air.

• Signs should be posted to indicate the location of materials containing asbestos.

Important reminders should be followed when disposing asbestos:

• Label wastes containing materials with asbestos before disposal. • Containers used to dispose of asbestos must follow all the requirements. • Warning signs should be put on every material that contains asbestos.

Personal Protective Equipment (PPE) must be worn when dealing with asbestos.

9.15.2 Lead

Because lead is very easy to work with and resistant to corrosion it is extensively used in building construction, external coverings of roofing joints, pipe solder and paints.

• Lead is a potent neurotoxin that accumulates in soft tissues and bone over

time and causes blood and brain disorders.

• Lead may still be found in harmful quantities in vinyl (such as that used for

tubing and the insulation of electrical cords).

• Old paint should not be stripped by sanding, as this produces inhalable dust.

9.15.3 Related industrial illnesses

9.15.3.1 Silicosis

Silicosis is caused by exposure to respirable crystalline silica dust. Crystalline silica is a basic component of soil, sand, granite, and most other types of rock, and it is used as an abrasive blasting agent. Silicosis is a progressive, disabling, and often fatal lung disease. Cigarette smoking adds to the lung damage caused by silica. Effects of Silicosis

• Lung cancer – Silica has been classified as a human lung carcinogen.

• Bronchitis/Chronic Obstructive Pulmonary Disorder.

• Tuberculosis – Silicosis makes an individual more susceptible to TB.


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• Scleroderma – a disease affecting skin, blood vessels, joints and skeletal

muscles.

• Possible renal disease.

Symptoms of Silicosis

• Shortness of breath; possible fever.

• Fatigue; loss of appetite.

• Chest pain; dry, non-productive cough.

• Respiratory failure, which may eventually lead to death.

Sources of Exposure

• Sandblasting for surface preparation.

• Crushing and drilling rock and concrete.

• Masonry and concrete work (e.g., building and road construction and repair).

• Mining/tunneling; demolition work.

• Cement and asphalt pavement manufacturing.

Preventing Silicosis

• Use all available engineering controls such as blasting cabinets and local

exhaust ventilation. Avoid using compressed air for cleaning surfaces.

• Use water sprays, wet methods for cutting, chipping, drilling, sawing, grinding,

etc.

• Substitute non-crystalline silica blasting material.

• Use respirators approved for protection against silica; if sandblasting, use

abrasive blasting respirators.

• Do not eat, drink or smoke near crystalline silica dust.

• Wash hands and face before eating, drinking or smoking away from exposure

area.

9.16 Safe Construction Practices

The most common accidents in work spaces still under construction are entrapment/confinement, falls, traffic/movement and getting hit by materials/equipment.

9.16.1 Scaffolding

A scaffold plan should be prepared and provided by the person in charge of all scaffold work. To develop an effective and useful scaffold plan consult with:

• a scaffold designer, for example, to discuss the design loads and the capability of the structure to support any additional loadings

• the builder or principal contractor, for example, to assess the location of underground drains or pits. The work should be planned so as to avoid excavating service trenches under, through or adjacent to scaffolds; and


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• workers, workplace health and safety committees, and workplace health and safety representatives (WHSR), regarding erecting, dismantling, maintaining and altering the scaffolding.

The scaffold plan should include a site layout plan and detail the elevations and sections of the scaffold. It is to be made available for inspection at the worksite. The scaffold plan should address the following issues:

• basis of design • foundations (including ground conditions and loadings) • supporting structure • access and egress • tying • bracing • type of scaffold • edge protection

There are several types and kinds of scaffolding that may be used depending on the kind of construction/renovation work being done. The safety requirements for each kind of scaffolding that maybe used, particularly for mobile scaffolding, should be strictly complied with.

Public safety must be guaranteed through perimeter containment screening to protect persons from falling objects.

9.16.2 Aerial lifts, Cranes, rigging and overhead hazards

The major causes of fatalities are falls, electrocutions, and collapses or tip overs.

1. Ensure that workers who operate aerial lifts are properly trained in the safe

use of the equipment.

2. Maintain and operate elevating work platforms in accordance with the

manufacturer’s instructions.

3. Never override hydraulic, mechanical, or electrical safety devices.

4. Never move the equipment with workers in an elevated platform unless this is

permitted by the manufacturer.

5. Do not allow workers to position themselves between overhead hazards, such

as joists and beams, and the rails of the basket. Movement of the lift could

crush the worker(s).

6. Maintain a minimum clearance of at least 10 feet, or 3 meters, away from the

nearest overhead lines.

7. Always treat powerlines, wires and other conductors as energized, even if they

are down or appear to be insulated.

8. Use a body harness with a lanyard attached to the boom or basket to prevent

the worker(s) from being ejected or pulled from the basket.

9. Set the brakes, and use wheel chocks when on an incline.

10. Use outriggers, if provided.


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11. Do not exceed the load limits of the equipment. Allow for the combined

weight of the worker, tools, and materials.

12. Inspect all rigging equipment prior to each lift, this should include all slings,

chains, ropes, and like materials used to support and lift materials.

13. Remove from service any defective equipment immediately.

14. Be sure to inspect all hooks, clamps, and other lifting accessories for their

rated load.

15. Clearly communicate to all employees on site that no one is permitted to work

under loads.

10 Electrical safety

Electricity, if not inspected, can lead to serious work place hazards exposing employees to electrocution, electric shock, electrical burns, fire, fall and explosions. Statistics reveal that electrocution accounts for close to 5% of workplace fatalities. Some general rules should be observed when dealing with electrical safety.

• Only authorized personnel, licensed for electrical work, are permitted to repair, adjust, test or service electrical equipment. In certain regions, this would entail that the factory hires an external certified contractor.

• Follow applicable local and national codes and regulations at all times. Live electrical equipment or electrical component parts must be grounded, isolated or provided with some other means of protection to prevent potential exposure to employees.

• All electrical equipment must be in safe condition before using. Remove defective equipment by maintenance department until it is repaired or replaced.

• Personal portable electrical equipment, such as heaters, etc. must be approved prior to use.

• Do not overload electrical equipment or electrical outlets. Only use approved extension cords and outlets.

• Only use extension cords that are intended for the equipment and conditions associated with the operation. Cords must be grounded and inspected prior to use to assure proper grounding.

• Electrical devices like junction boxes and distribution panels must be closed, undamaged and not be misused for direct connection with machines.

• Wires must be well insulated, replaced if damaged, protected against mechanical damage and damage from heat where necessary.

• Clear warning sign should be erected at high voltage area to avoid any “non-authorized access” and “improper storage inside the high voltage area”. Warning signs should be installed on all equipment and facilities required by law.

• Regular maintenance and inspection program should be carried out for all electrical equipment.


11 Machinery/Plant safety

Moving machine parts have the potential for causing severe workplace injuries. Therefore, any machine part, function, or process that may cause injury must be safeguarded. When the operation of a machine or accidental contact with it can injure the operator or others in the vicinity, the hazards must be either controlled or eliminated. Examples of preventative measures are:

• Designing the machine to have no dangerous parts or no exposed dangerous parts. The following items are listed in order of preference, and may be used in combination:

o Eliminating the cause of the danger o Reducing or eliminating the need for people to approach the dangerous

part(s) of the machine o Making access to the dangerous parts difficult (or providing safety

devices so that access does not lead to injury) o The provision of protective clothing or equipment o Fail-safe mechanism is in place to protect the operators.

• Making any dangerous parts of the machine inaccessible to people. To do this

the guarding system should incorporate the following principles: o Select the appropriate guard for the particular machine o Ensure that the guard cannot be removed or defeated o Ensure that the guard does not constitute a secondary hazard. o Preference should always be given to the simplest type of guard, that

is, a fixed guard with no moving parts.

Warning signs

Electrical Panel fully covered


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• Training the machine operators (and all personnel who may approach the machine) in the appropriate operating safety procedures. Ensuring that the operators understand the procedures and that they use them at all times.

Safeguards must meet the following minimum general requirements to protect a worker against mechanical hazards:

• The safeguard must prevent hands, arms, and any other part of a worker’s body from making contact with dangerous moving parts.

• Workers should not be able to easily remove or tamper with the safeguard. • The safeguard should ensure that no objects can fall into moving parts. • Create no new hazards. • Create no interference.

Fixed guards provide the highest standard of protection, and should be used, where practical, where access to the dangerous area is not required during normal operation. The following gives guidance on the selection of safeguards:

• Where access to the danger area is not required during normal operation: o Fixed guard, where practical o Distance guard o Trip device

• Where access to the danger area is required during normal operation: o Interlocking guard o Automatic guard o Trip device o Adjustable guard o Self-adjusting guard o Two-hand control

11.1 Control of Hazardous Energy/Lock-Out Tag-Out

"Lockout/Tagout (LOTO)" refers to specific practices and procedures to safeguard employees from the unexpected re-energizing or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities.

• Factories must have a written lock-out/tag-out and maintenance procedures to keep maintenance personnel and equipment operators safe during operations such as lubricating, clear or un-jamming of machines, needle changes, or changing of dies or machine parts.

• Each piece of machinery or equipment must have its own electrical, pneumatic, or hydraulic disconnect switch or valve so that the individual machine or piece of equipment can be isolated from the others.


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General Lock-Out/Tag-Out Procedure

• Identify the primary equipment to be maintained, and any additional equipment associated with it.

• Review the specific lock-out/tag-out procedure(s) for the device or equipment. • Notify the workers (e.g., operator, team members, and supervisors) who use

the equipment or work around it that lockout/tag-out and maintenance work is to be performed.

• Turn the equipment off (follow normal shut-down procedures). • Isolate all associated energy sources and discharge the stored energy until

you have achieved a zero state (e.g., bleed all pressurized lines, discharge electrical circuits).

• Block and/or restrict all machine parts that may move and therefore pose a hazard during maintenance work.

• Attach a tag to the affected equipment. • Attach a lock to isolate equipment from energy sources. • Turn the machine’s power sources on as a test. The equipment should not be

operable and any stored energy should be completely discharged. • Turn equipment power sources back to the “OFF” position. • Complete service, repairs and/or adjustments.

o Restore equipment to service. o Replace all covers and safety devices. o Inspect equipment. o Verify all workers are clear of the equipment. o Remove locks and tags. o Turn equipment energy source(s) back to the “ON” position. o Test equipment for proper function.

• Notify affected workers that equipment is ready for use and lock-out/tag-out is no longer in use.

Developing and implementing a written prevention program at least including the following:

• Identify the types of activities and the machines and equipment that require lock-out/tag-out of hazardous energy sources.

• Make sure maintenance workers are trained and authorized to perform lockout/tag-out of equipment they maintain or service. Make sure those who work with or around this equipment are trained to know what lock-out/tag-out procedures are for. Provide authorized workers with standardized lock-out/tag-out devices.

• Make sure new or modified equipment is capable of having all energy sources locked out (rather than simply tagged out).

• Evaluate the lock-out/tag-out program each year. • Monitor authorized workers perform lockout/ tag-out each year and recertify

them. Training must ensure that employees understand the purpose, function, and restrictions of the energy-control program. Employers must provide training specific to the needs of "authorized," "affected," and "other" employees.


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"Authorized" employees are those responsible for implementing the energy-control procedures or performing the service or maintenance activities. They need the knowledge and skills necessary for the safe application, use, and removal of energy-isolating devices. They also need training in the following:

• Hazardous energy source recognition; • The type and magnitude of the hazardous energy sources in the workplace;

and • Energy-control procedures, including the methods and means to isolate and

control those energy sources.

"Affected" employees (usually machine operators or users) are employees who operate the relevant machinery or whose jobs require them to be in the area where service or maintenance is performed. These employees do not service or maintain machinery or perform lockout/tagout activities. Affected employees must receive training in the purpose and use of energy-control procedures. They also need to be able to do the following:

• Recognize when the energy-control procedure is being used, • Understand the purpose of the procedure, and • Understand the importance of not tampering with lockout or tagout devices

and not starting or using equipment that has been locked or tagged out.

All other employees whose work operations are or may be in an area where energy-control procedures are used must receive instruction regarding the energy-control procedure and the prohibition against removing a lockout or tagout device and attempting to restart, reenergize, or operate the machinery.

12 Chemical safety

Every worker has both the need and the right to know the hazards and identities of substances / chemicals they are exposed to, when at work. It is important to implement a documented chemical safety plan, regardless of the number of chemicals used at the factory or their levels of hazard.

• Perform Hazard Assessment Prior to the usage of new chemicals or processes, assessment of potential hazards must be completed. Supervisors should develop and promulgate process specific guidelines and protective procedures. If not conducted yet, hazard assessment needs to be completed, documented and communicated.

• Minimize Chemical Exposures

It is prudent to minimize all chemical exposures. As very few chemicals are without hazards, hazard assessment will aid in deciding and arriving at a matrix of exposure control measures, including: substitution (wherever possible), engineering controls, administrative controls and personal protective equipment. General precautions should be documented and adopted, for use by all workers.


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• Avoid Underestimation of Risk

Even for substances of known significant hazard, exposure should be minimized. Special precautions must be taken when working with substances which present special hazards. One should assume that any mixture will be more toxic than its most toxic component, and that all substances of unknown toxicity are toxic.

• Provide Adequate Ventilation

The best way to prevent exposure to airborne substances is to prevent their escape into the working atmosphere by use of exhaust fans, hoods and other ventilation devices. All workstations where chemicals are used (like spot cleaning) must be isolated (by way of providing a separate enclosure) and should be strategically located near windows or other openings. Exhaust air must be completely removed from the workplace into the outside or filtered.

12.1 Building blocks of chemical safety plan

The major elements of a chemical safety plan are discussed below.

• Procurement and distribution Whenever a request for procurement (replacement or replenishment) of chemical is raised the following should be confirmed (with internal staff and vendor, as required).

o Process control specifications indicating what the chemical is to be used

for o Assurance that the requested chemical is the least hazardous, amongst

available options, for this process o Where it is going to be used o Assurance that engineering controls, if required, are adequate o Before any substance is received, information of proper handling,

storage and disposal must be received and communicated o Containers without adequate labels, identifying the contents of the

container and associated hazards, should not be accepted.

Chemicals will be issued to authorized requestors only. Appropriate equipment like hand pumps should be used to transfer chemicals from one container to the other. Crude methods like pouring from container to container directly using hose without suction arrangement can lead to spillage / exposure and should be strictly avoided.

• Chemical storage

Chemicals should be stored in a location earmarked for the purpose and the said location should comply with the guidelines provided below (according to the size of the chemical storage room).

o Emergency lighting

Chemical storage area shall be provided with adequate emergency lights with a minimum of one hour individual battery backup.


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o Floors and aisles

� Floor finish should be anti-slip and made impermeable. � Protected against spillages to the outside, ground or

groundwater. � Aisles should be at least 1,1m wide. � Doors should not directly open into passageways.

o Exits/Entrances

� Both regular exits and emergency exits shall be marked clearly. � Doorways shall be unobstructed and swing in the direction of the

escape. � Exits should be entirely free of the presence of hazardous

materials.

o Ventilation � Chemical storage area should be ventilated separately from the

rest of the building and exhausts must be terminated at a safe distance from the building.

� Storage area should be ventilated by at least four changes of air per hour. Isolate the chemical storage exhaust from the building ventilation system.

o Chemical storage

� Stored chemicals should be arranged in compatible families rather than in alphabetical order.

� Avoid storing chemicals on shelves above eye level. � Chemicals must be away from water sources. � Appropriate secondary containment arrangement needs to be

provided. � Chemicals stored at workplace or at mixing area should not

exceed the maximum amount of the daily usage at workplace. � Here are some guidelines for classifying chemicals and their

corresponding storage method:


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Class of Chemicals

Recommended Storage Method

Incompatibles Chemical Example

Corrosive - Acids (Inorganic)

Store in a separate protected acid storage cabinet (DO NOT store

on metal shelves)

Flammable liquids and solids, Bases, oxidizers, Organic

acids

Hydrochloric acid, sulfuric acid, chromic

acid, nitric acid

Corrosive - Acids (Organic)

Store in a separate protected acid storage cabinet (DO NOT store

on metal shelves)

Flammable liquids and solids, Bases,

oxidizers, Inorganic acids

Acetic acid, Lactic acid, Trichloroacetic

acid

Bases Store in a separate

storage cabinet

Flammable liquids, Oxidizers, poisons,

and acids

Potassium hydroxide, Sodium hydroxide

Flammable (Liquid and Solid)

Store in a flammable storage cabinet, dry

cool area

Acids, Bases, Oxidizers, and

poisons

Acetone, Benzene, Methanol, Toluene,

Solvents

Oxidizers

Store in non-combustible cabinet

with secondary containment

Reducing agent, Flammables, organic

materials and combustibles

Sodium hypochlorite, potassium

permanganate, Peroxides, Nitrates,

Perchlorates

Water Reactive Chemicals

Store in dry, cool location protected

from sprinkler system, label WATER REACTIVE

Oxidizers and water

Sodium metal, Potassium metal, Lithium aluminum

hydride

o Other facilities � Tri-Class ABC and size (minimum 5.5 Kg gross weight) fire

extinguishers should be available in the chemical stores area. A fire alarm calling point is mandatory.

� An eyewash station along with provision for head shower and fire blanket should be provided. Care needs to be taken in deciding the location of eyewash station and proper means of draining water without wetting storage area must be established.

� A separate storage area for PPEs like aprons, nose-masks, goggles should be provided within the facility.

� A separate wash area near the exit of the chemical storage area should be provided with adequate supplies of soap solution and towels.

� An emergency telephone should be available in the chemical storage area.

� Proper drain facilities to be provided and ensure that the chemical storage drain does not go to the general drain or into the soil below the storage.

o Security

� Only authorized personnel, preferably wearing an appropriate badge, should be allowed to enter chemical storage area. Procedure and controls should be in place to prevent any unauthorized access to area.


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� An "Authorized Personnel Only" sign must be displayed at the entrance.

� For security reasons, all exits and entrances should lead strictly to and from chemical storage area and there shall be no other work area for which access is through the chemical storage area.

• Housekeeping, maintenance and inspection of the chemicals room

o Cleaning � Floor and equipment should be cleaned regularly � Employees involved in housekeeping activities at the chemical

storage area need to be properly trained to carry such activities in a safe manner.

o Inspections

� Chemical safety inspections need to be conducted, at least once every quarter, to ensure that adequate safety equipment is available and functioning, personal protection is available, chemicals are properly stored, MSDSs are readily available, good housekeeping is being practiced and that the spill kit and first aid kits are adequately stocked.

� Chemical safety inspections will have to be documented showing details of necessary corrective actions taken.

o Maintenance

� Eye wash and head shower arrangement, ventilation and other equipment provided at the chemical storage area should be inspected at least once quarterly.

� Procedures shall be established to prevent the use of inoperable or out-of-service protective equipment.

� All maintenance activities carried out must be documented to demonstrate compliance.

• First aid kit in the chemicals room and medical examination

o First aid kit � Need to ensure that a first aid box with all required contents is

provided at the chemical storage area. � At least two employees, who are regularly employed in or near

the chemical storage, must be provided training to administer first aid and on procedures to be followed upon exposure of chemicals.

o Medical examination

� Workers whose nature of job (spot cleaning and printing workers, workers involved in housekeeping of the chemical storage area etc) exposes them to chemicals need to go through a medical examination, at least once annually.

� Results of such medical examinations and measures taken to reduce exposure, with respect to those workers whose medical examinations reveal negative impact, must be documented.


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• Personal protective clothing and equipment to be used handling chemicals o Protective clothing such as gloves, aprons or suits shall be provided and

used during distribution, transfer and usage of chemicals. o Appropriate type of masks (fitted with carbon filter) and goggles need

to be provided to workers who are involved in jobs related to chemical storage, related housekeeping, transfer (receipt and issue) and usage of chemicals in work areas (spot cleaning, washing, color kitchen, printing etc).

• Communication – Signage and label of chemicals

o Notice and signs � All communication must be in the regional language as

understood by majority of the workers. Prominent signs and labels of the following types shall be posted.

� Emergency telephone numbers. � Location signs for eyewash and head shower, fire extinguishers,

spill kit and first aid kit. � Warning signs at areas or equipment where special or unusual

hazards exist.

o Labels and labelling � All chemical containers (irrespective of size or familiarity) shall

be labeled in the regional language as understood by majority of the workers.

� The label shall, at a minimum, contain the following information: o Name of chemical - Trade name and chemical name o Hazard warning - includes physical hazards, e.g.

flammable, combustible liquid, compressed gas o Health hazards, e.g. corrosive, carcinogenic, toxic, etc. o Safety tips when handling or storing the chemicals, e.g.

using gas masks and rubber gloves, etc.

o MSDS (Material Safety Data Sheet) � MSDS with respect to every chemical should be displayed at

locations where chemicals are stored and used. � MSDS displayed should provide the following information:

o Name of chemical - Trade name and chemical name o Physical properties like appearance, odor and state (for

sake of identification) o Chemical properties like boiling point and solubility in

water o Fire safety info like flash point, extinguishing media,

unique fire hazard etc o Reactivity hazard including incompatible substances o Health hazards, e.g., corrosive, carcinogenic, toxic,

teratogenic, etc. o Unique hazards like violent reactivity with water (as in

Sodium perborate), oxidizer (as in Hydrogen peroxide), carcinogenic (as in Benzene) etc

o Specific emergency and first aid procedures


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o Precautions for safe storage, handling and use o Control measures o Waste disposal method o Hazard warning symbols - includes physical hazards, e.g.,

flammable, combustible liquid, compressed gas

• Information and training on the use of chemicals o The objective of training and information dissemination is to assure

that all individuals at risk are adequately informed about the work involving chemicals, its risks, and what to do if an exposure occurs. Hazard communication training is required of all employees who handle, transport or use chemicals, or who work in areas where chemicals are stored.

o Such information shall be provided at the time of the employee’s initial assignment to a work area where hazardous chemicals are present or during the induction session, in case of fresh recruits.

• Chemicals disposal

Safe disposal of hazardous wastes can be time-consuming and expensive. Every effort should be made to limit the amount of hazardous wastes generated. Wherever possible, factory management should plan processes carefully and order only what is required. Factory management should ensure that waste disposal (like dry sludge from the effluent treatment plant, used machine oil, etc.) is done in strict accordance to the provisions of local law.

o Unwanted chemicals and related wastes should be disposed of promptly, by using appropriate procedures. Such materials, as well as chemicals that are no longer needed, should not accumulate in the laboratory.

o Hazardous chemicals must be packaged for disposal as follows: � Containers must be suitable for contents. Example: Hydrofluoric

acid in plastic bottles. � Containers must be tightly closed. � Do not overfill containers; expanding vapors may cause

containers to break. � Containers must not be damaged. � Cracked caps should be completely sealed with plastic tape. � Containers must be labeled.

12.2 Globally Harmonized System of Classification and Labeling of Chemicals

The Globally Harmonized System of Classification and Labeling of Chemicals or GHS is an internationally agreed upon system, created by the United Nations. It is

All chemicals used should be in line with PUMA’s restricted substances

list as detailed in the PUMA.Safe Handbook for Environmental Standards.


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designed to replace the various classification and labeling standards used in different countries by using consistent criteria for classification and labeling on a global level. The GHS is a system for standardizing and harmonizing the classification and labeling of chemicals. The elements in the GHS supply a mechanism to meet the basic requirement of any hazard communication system, which is to decide if the chemical product produced and/or supplied is hazardous and to prepare a label and/or Safety Data Sheet as appropriate. The GHS classification system is a complex system with data obtained from tests, literature, and practical experience. The main elements of the hazard classification criteria are summarized below:

12.2.1 Physical Hazards

The GHS physical hazards criteria, developed by the ILO and UNCETDG, were largely based on the existing criteria used by the UN Model Regulation on the Transport of Dangerous Goods. The GHS physical hazards are briefly described below.

• Explosives • Flammable Gases • Flammable Aerosols • Oxidizing Gases • Gases Under Pressure • Flammable Liquids • Flammable Solids • Self-Reactive Substances • Pyrophoric Liquids • Pyrophoric Solids • Self-Heating Substances • Substances which, in contact

with water emit flammable gases • Oxidizing Liquids • Oxidizing Solids • Organic Peroxides • Corrosive to Metals

12.2.2 Health and Environmental Hazard

The GHS health and environmental hazard criteria represent a harmonized approach for existing classification systems as following

• Acute Toxicity • Skin Corrosion/Irritation • Serious Eye Damage/Eye Irritation • Respiratory or Skin Sensitization • Germ Cell Mutagenicity • Carcinogenicity • Reproductive Toxicology


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• Target Organ Systemic Toxicity - Single Exposure • Target Organ Systemic Toxicity - Repeated Exposure • Aspiration Toxicity • Hazardous to the Aquatic Environment

o Acute aquatic toxicity o Chronic aquatic toxicity

� Bioaccumulation potential � Rapid degradability

12.2.3 Classification of Mixtures

The process for the classification of mixtures is based on the following steps:

1. Where toxicological or ecotoxicological test data are available for the mixture

itself, the classification of the mixture will be based on that data;

2. Where test data are not available for the mixture itself, then the appropriate

bridging principles should be applied, which uses test data for components

and/or similar mixtures;

3. If (1) test data are not available for the mixture itself, and (2) the bridging

principles cannot be applied, then use the calculation or cut-off values

described in the specific endpoint to classify the mixture.

12.3 Hazard communication

As with many existing systems, the communication methods incorporated in GHS include labels and MSDS’s. The GHS attempts to standardize hazard communication so that the intended audience can better understand the hazards of the chemicals in use. The GHS has established guiding principles:

• The problem of trade secret or confidential business information has not been addressed within the GHS, except in general terms. For example, non-disclosure of confidential business information should not compromise the health and safety of users.

• Hazard communication should be available in more than one form (for example, placards, labels or MSDS’s).

• Hazard communication should include hazard statements and precautionary statements.

• Hazard communication information should be easy to understand and standardized.

• Hazard communication phrases should be consistent with each other to reduce confusion.

• Hazard communication should take into account all existing research and any new evidence.

12.3.1 GHS Label Elements

The standardized label elements included in the GHS are:


• Symbols (hazard pictograms): Convey health, physical and environmental hazard information.

Examples of all the pictograms and downloadable file can be accessed on the UN website for the GHS at http://www.unece.org/trans/danger/publi/ghs/pictograms.html

For further details of how to allocate pictograms according to the UN GHS please see Annex I of the UN GHS and three new harmonized hazard warning symbols for labels (known as ‘pictograms’)

• Signal Words: "Danger" or "Warning" will be used to emphasize hazards and indicate the relative level of severity of the hazard.

• Hazard Statements: Standard phrases assigned to a hazard class and category that describe the nature of the hazard. An appropriate statement for each GHS hazard should be included on the label for products possessing more than one hazard.

The additional label elements included in the GHS are:

• Precautionary Statements: Measures to minimize or prevent adverse effects.

• Product Identifier (ingredient disclosure): Name or number used for a hazardous product on a label or in the MSDS.

• Supplier identification: The name, address and telephone number should be provided on the label.

• Supplemental information: Non-harmonized information on the container of a hazardous product that is not required or specified under the GHS.

12.3.2 GHS Label Format

The GHS includes directions for application of the hazard communication elements on the label. In particular, it specifies for each hazard, and for each class within the hazard, what signal word, pictogram, and hazard statement should be used. The GHS hazard pictograms signal words and hazard statements should be located together on the label. The actual label format or layout is not specified in the GHS.


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12.3.3 GHS Material Safety Data Sheet or Safety Data Sheet

The safety data sheet (The GHS has dropped the word “material” from material safety data sheet. It will now be called the safety data sheet or SDS) is specifically aimed at use in the workplace. It should provide comprehensive information about the chemical product that allows employers and workers to obtain concise, relevant and accurate information that can be put in perspective with regard to the hazards, uses and risk management of the chemical product in the workplace. The SDS should contain 16 sections. While there were some differences in existing industry recommendations, and requirements of countries, there was widespread agreement on a 16 section SDS that includes the following headings in the order specified:

1. Identification 2. Hazard(s) identification 3. Composition/ information on ingredients 4. First-aid measures 5. Fire-fighting measures 6. Accidental release measures 7. Handling and storage 8. Exposure control/ personal protection 9. Physical and chemical properties 10. Stability and reactivity 11. Toxicological information 12. Ecological information 13. Disposal considerations 14. Transport information 15. Regulatory information 16. Other information

For further details regarding the Guidance on the preparation of Safety Data Sheet, please refer to the following link: http://www.unece.org/fileadmin/DAM/trans/danger/publi/ghs/ghs_rev03/English/08e_annex4.pdf

13 Product Process

13.1 Potassium Permanganate

Potassium permanganate spray is done on jeans to take a bright effect on sand blast area. One important thing about potassium permanganate spray is that it is usually a sporting process to increase the effect of sand blast. Important procedures for using potassium permanganate are as follows:

• Permanganate potassium spray operations must be conducted in an area of

the factory that is separated from other areas and with a physical barrier.

• Install local exhaust ventilation and fans that direct air flow away from

workers.


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• Label containers with permanganate potassium in the work place and in the

chemical storage.

• Provide trainings concerning chemical hazards and controls for all employees

involved, as how to storage and handle.

• Airborne exposure limit is 1 mg/m3 average a 10-hour workshift and 3 mg/m3,

not to be exceeded during any 15 minute work period.

• Exposure to hazardous substances should be routinely evaluated. This may

include collecting personal and area air samples.

• Periodically conduct medical tests for workers that handle this chemical.

• Store in tightly closed containers in a cool, well-ventilated area away from

combustibles and organics. Protect containers from physical damage.

• Use a vacuum or a wet method to reduce dust during clean-up. Do not dry

sweep.

• Operators must wear proper PPE that protects against KmnO4 permeation and

proper respiratory protection.

• An eyewash station should be installed located close to the potassium

permanganate spray area, for easy use if fumes get in the workers’ eyes.

13.2 Ozone Generators

Ozone generators are commonly used by factories as a bleaching in the fabric finishing process. It is also used for laundry with high performance and cleaning efficiency. Systems that generate ozone and inject it into laundry water can dramatically reduce the hot water used in large laundry operations, as well as reducing the amount of cleaning chemicals used producing cleaner, brighter linens and clothing. Also, it is environmental friendly since it could reduce the hot water consumption by as much as 95%. Ozone is a gas with no color, acrid odor and is a powerful oxidant. The molecule of ozone is unstable and tends to break again and that is why Ozone cannot be stored in any manner and thus must be generated in-situ with an ozone generator. However Ozone is also an irritant gas and may cause health effects that range from irritation of the eyes, nose, throat and chest to pulmonary edema, severe bleeding and even death. Ozone as being a strong oxidizing agent can pose a fire or explosion hazard under certain circumstances.

Important requirements are listed below for using Ozone generators:

• Ozone generators must be separated from the rest of the factory by enclosing

them in their own room or by using a physical barrier or cover.

• Ozone generator must have a shut off switch located outside of the ozone

enclosed area and at least 10 meters away.

• Install a monitor inside the ozone chamber (or inside the drum of the tumbler)

in order to observe the ozone concentration in the system.

• Washer/Extractor/Tumbler doors must be interlocked and must not be capable

of opening until the ozone concentration is equal to or less than 1 ppm for low

pressure and vacuum systems or 0.4 mg/Nm3 for the G2 integrated system.


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• A monitor and an audible or visual alarm must be installed to alert workers if

ozone levels exceed 1 ppm in areas in which ozone generators are located.

• Evaluate ozone exposures to workers every year, using the OSHA ID 214

sampling method.

• Equipment associated with the ozone generator (such as pipes, pipe

connectors, and clamps) must be made of corrosion-resistant materials and

must be strong enough to withstand the pressure generated by the ozone

finish process.

• Do not store any kind of chemical in the same area of the ozone generator.

• Employees must be trained on the hazards of ozone generators and gas.

• Have written procedures for ozone generators for emergencies, how to use

generators, etc.

• Only specialized workers can do the maintenance.

• Excess or exhaust ozone must be ventilated through an ozone-destruct unit.

The ozone-destruct unit may use either thermal/steam or catalytic conversion

technology and must destroy ozone, thereby exhausting carbon dioxide and

oxygen to the outside air.

• In cases of leak or ozone generator malfunction, proper PPE should be worn

which includes Self Contained Breathing Apparatus (SCBA)

13.3 Abrasive Blasting

Abrasive is a general term used to describe the act of propelling very fine bits of material at high-velocity to clean or etch a surface. Sand used to be the most commonly used material that causes the lung disease silicosis by extended inhalation of the dust created by sand. Include excessive noise, inhalation of airborne dust particles, eye contact and swallowing of dust. Prohibition of Sandblasting Due to the known adverse and potentially fatal health effects of sandblasting (danger of development of silicosis) on the workers carrying out the operation, the usage of sandblasting for Denim production or any other PUMA related production is generally not permitted. Here are some important requirements for abrasive materials and blasting operation:

• Abrasive material must not contain more than 1% crystalline silica. o Abrasive materials must be tested using NIOSH 7500 or an equivalent

test method.

o When crystalline silica is present in the abrasive material, factories

must conduct a hygiene assessment to ensure worker exposure to

airborne silica is below regulatory standards and acceptable limits. An

initial medical examination to ensure abrasive blasting workers are

capable of doing the job is required as well.


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• Abrasive Blasting operations must be conducted in an area of the factory that is separated from other areas and with a physical barrier.

• Factories must provide ventilation for abrasive blasting operations that meets the following requirements:

o Air flow is directed away from the worker.

o The ventilation system for the abrasive blasting area is separated from

the rest of the factory.

o Outgoing (exhaust) air is located away from the incoming (intake) air.

• Provide hearing protection and protective eyewear (e.g. goggles, spectacles or prescription safety glasses).

• Factories shall establish and implement a procedure for dust collection and cleaning and maintenance of abrasive blasting equipment.

• Workers must wear the right PPE when doing abrasive blasting operations. • Trainings about abrasive blasting should be given for workers involved in the

process. • Abrasive materials must not be mixed. • Operators must use respiratory protection: personal air purifying respirators or

supplied-air, shoulder-mounted hoods or an N95 dust mask (either of these is

a best management practice).

• Operators must wear full-body, hooded coverall and boot/ shoe covers to

prevent dust from getting on clothes. • Operators should practice good personal hygiene (e.g., no eating, smoking or

drinking in the abrasive blasting area; washing up before leaving the abrasive

blasting area) to avoid dust exposures.

• An eyewash station should be located close to the abrasive blasting booth or

area, for use if dust gets in the workers’ eyes.

13.4 Sandblasting substitutes

The urgency to decrease silica exposures has produced excellent research at NIOSH

on the industrial hygiene aspects of blasting substitutes. Yet, there has been little

research on the health effects that are not associated with chemical exposures, such

as ergonomic effects, and the economics of the substitutes. With all the much

needed focus on technologies to reduce silica exposure, we must be mindful of

introducing new hazards into the workplace. In order to fully evaluate an

intervention, we need to take an integrated approach to the workplace. Further, for

any of this research to be useful for contractors in deciding which method to choose,

we need to have full cost accounting of each of the technologies.

13.4.1 Glass

Though it might seem worse than using sand, recycled glass grit has been

successfully substituted for sand in the sandblasting process. The glass is extremely

tiny. Unlike sand particles, the glass particles are much heavier, and they won't dust

up in the air and cause irritation to the eyes and lungs. However, you still must wear


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safety equipment to protect your eyes, face and lungs from accidentally coming into

contact with the glass particles.

13.4.2 Water

Another alternative to sandblasting is to use high pressure water. Keep water under

extremely high pressure, and spray it against a surface with a force great enough to

peel paint or to clean grit out of concrete pores. Using water instead of sandblasting

is much safer environmentally since water doesn't harm the environment, and you

don't have to clean it up; it will evaporate in time. Additionally, there isn't anything

added to the water throughout the process; it's just pure water under high pressure.

13.4.3 Dry Ice

Dry ice blasting is also an option you can use over traditional sandblasting methods.

You must keep dry ice at extremely cold temperatures, but you can freeze it into

very small particles. You can fire these particles at a surface to act as an abrasive,

but the dry ice evaporates completely in a short period after it strikes the surface. As

such, dry ice as an abrasive requires no real cleanup, and it doesn't pollute the

environment; however it is more expensive than sand and other silica-based grit and

dry ice is harder to keep cold and ready.

13.5 Spraying

Pigments are used for coloring fabric. Most pigments used in manufacturing are dry colorants, usually ground into a fine powder; this is applied to the fabric using the spray method. Tints and pigments should not contact the skin or eyes and should not be inhaled or swallowed. Listed below are the important requirements for spraying operation:

• Fans and ventilation system that direct air flow away from workers.

• Wear gloves that protect against permeation of tints and dyes.

• Use protective eyewear.

• Wear dust mask for protection against inhalation of tints and dyes.

• Safety shower and eye wash should be installed in immediate area.

• Solutions must be mixed in well ventilated or open area. Personal protective

equipment is required while mixing.

13.6 Screen Printing

Screen printing is a method in which ink is applied directly to the surface to be printed. The image to be printed is photographically transferred to a very fine fabric (the screen). Important safety guidelines for screen printing are as follows:

• Skin must not come in contact with hot objects and ventilation is adequate.


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• Fans and ventilation systems must direct air flow away from workers.

• Gloves should be worn to protect hands from hot objects.

• Pigment and dye containers must be labeled and in good condition.

• Oil-based paints and dyes should be stored away from heat sources.

13.7 Handicraft and Hand Painting Handicraft

Handicraft includes: sanding, scraping, etc. It is any manual abrasion of fabric or garments by hand or with a hand held sanding tool. Important implementation for handicraft should cover the following:

• Training must be provided on proper work method.

• Airborne dust levels should be minimized.

• Wear hearing protection if noise level is over 85 dBA.

• Use protective eyewear when using power tools.

• Wear dust mask to protect against inhalation of dust when applicable.

Hand painting

Hand painting is the manual application of paints, tints or dye, using a hand-held brush. Operation should optimize ergonomic practices, avoid electrical hazards, and keep airborne dust to a minimum.

• Material Safety Data Sheet (MSDS) for paint should be available for review.

• Wear personal protective equipment as recommended in the MSDS.

13.8 Laser Engraving

This process involves the use of lasers to fade dyes, giving garments a worn and abraded appearance. This technique may also be used to create faded images or letters. Listed below are implemented procedures for engaging in laser engraving:

• Physical barriers must be erected to prevent a worker from being pinned or hit

by moving robotic equipment.

• Danger, Warning or Caution signs, indicating hazards, should be posted

conspicuously to warn onlookers.

• Install exhaust ventilation that directs laser generated air contaminants away

from the work area and out of the building.

• An alarm, warning light, or verbal countdown must be used to indicate that

the laser is about to start up.


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• Make sure protective housings around the laser are interlocked so the laser

shuts down if the housing is opened during operation or for maintenance.

• Wear proper PPE for protection while engaging in laser printing.

13.9 Confined space, Sanitation and conditions of welfare facilities

Confined space -- means a space that:

• is large enough and so configured that an employee can bodily enter and

perform assigned work; and

• has limited or restricted means for entry or exit ( for example, tanks, vessels,

silos, storage bins, hoppers, vaults, and pits are spaces that have limited

means of entry.); and

• is not designed for continuous employee occupancy.

It recognizes that certain environmental conditions within confined spaces are capable of causing serious injury and/or death to anyone who enters the spaces without taking proper precautionary measures. Factory has established a permit authorization system to ensure that all hazards are evaluated and that appropriate safety measures and controls are taken prior to and during each entry into confined spaces. RESPONSIBILITIES

• Department Heads and/or Directors -- are responsible for implementing this

program and procedure within their departments, when applicable, and

ensuring that their personnel fully comply.

• Department Managers and/or Supervisors -- are responsible for identifying

their personnel who are required and authorized to enter confined spaces as

defined in this program and procedure. Managers/supervisors must ensure

that their personnel are properly trained and fully comply with the

requirements identified in this procedure.

• Employees -- are responsible for complying with the requirements of this

program and procedure. Employees shall inform their manager/supervisor of

any departures from this procedure.

• The Maintenance and Safety officer -- is responsible for the development and

maintenance of this program and procedure, providing resources for

equipment and personnel training, and for auditing all operating units and/or

departments for compliance to this procedure.

• Contract Personnel -- Outside contractors hired to perform operations that

include confined space entry shall be notified by the designated project

coordinator of these operating procedures prior to initiating the job. If the


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contractor has its own company procedure for confined space entry, they shall

provide a copy to the factory for review and approval.

GENERAL CONFINED SPACE ENTRY & PERMIT PROCEDURE 1.1 Confined Space Assessment

1.1.1 Identification of all confined space locations and their associated hazards.

1.1.2 Evaluation of the risk associated with each hazard.

1.1.3 Identification of control measures to reduce or eliminate the risk (e.g. entry

procedures, personal protective equipment, communication, training, etc.).

1.2 Labeling -- Warning signs or other means of notification shall be posted at the

entrance of each owned permit-required confined space to inform employees of its

existence and dangers. The notification wording shall be as follows:

1.3 Responsibilities of permit-required confined space entrants, entrant

supervisors and attendants.

1.4 Entry permit -- The entry permit is used to authorize entry into a permit-

required space and must identify:

1.4.1 The permit confined space to be entered;

1.4.2 The purpose of the entry;

1.4.3 The date and duration the permit is authorized for;

1.4.4 The authorized entrants’ names;

1.4.5 The authorized attendant(s);

1.4.6 The hazards of the space and measures used to isolate, eliminate and/or

control the hazards prior to entry;

1.4.7 Acceptable entry conditions;

1.4.8 Results of initial and periodic atmosphere testing (oxygen, %LEL, etc.)

1.4.9 Rescue or emergency contacts;

1.4.10 Personal protective equipment, communication equipment, rescue equipment;

and

1.4.11 Any additional permits that are required, such as lockout/tagout and/or hot

work,

1.4.12 Periodic calibration and pre-entry self calibration for all monitoring and test

equipment, rescue equipment

1.5 Entry termination -- The Confined Space entry shall terminate entry and

cancel the permit when:

a) The entry operations covered by the entry permit have been completed; or

b) A condition that is not allowed under the entry permit arises in or near the

permit space.

Each canceled/completed entry permit and relating documents, such as Confined

space training, incident, medical, and risk assessment shall be documented and

retained for one year by the department conducting or supervising the entry to allow

for auditing of the program’s effectiveness.

DANGER: CONFINED SPACE PERMIT REQUIRED PRIOR


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TRAINING All employees who are authorized as confined space entry supervisors, attendants

and entrants and sub-contractor personnel shall be trained and certified in these

operating procedures. The training shall be performed upon initial assignment of

personnel and refresher training will be conducted annually. The training can be

conducted by the department manager/supervisor or can be coordinated through the

Safety Department. The training shall include:

a) Definition of a permit-required confined space;

b) Hazards and control measures;

c) Entry procedures;

d) Responsibilities of the entrant and attendant; and

e) Rescue/Emergency procedures.

13.10 General conditions and materials handling

Sanitation is especially important for toilets, food preparing areas and bathrooms. The following guidance is applied to all production, office, warehouse and dormitories.

• Walls should be clean painted or tiled.

• The floor of working area should be maintained, and kept dry. Platforms,

mats, or other dry standing places should be provided for where wet

processes are used, drainage should be maintained, or appropriate waterproof

footwear should be provided.

• All floors, walkways, and stairs must be kept in good repair. Keep them free of

anything that may cause a slip or trip hazard.

• Do not allow waste materials to build-up in working areas (around saw horses,

cutting stations, tool boxes). Maintain an ongoing routine of waste disposal at

regular intervals.

• Maintain adequate lighting in all work areas.

• Use waste bins, garbage cans, and dumpsters to prevent the build-up of

debris.

• Ensure that there are no protruding nails on loose or fixed materials that may

snag clothing or cause an abrasion or puncture.

• Post signs and use danger or caution tape where hazards might not be readily

seen.

• Ensure that all ground surfaces are firm and level before setting scaffolds or

ladders.

• Aisles and exits should be clear of obstructions at any time.

• Smoking or eating in production areas or toilets should generally not be

permitted. A restaurant, canteen or dining area with sufficient space should be

provided for all employees to support this rule.

• Garbage / unused materials should be regularly removed


Example of garbage separation

13.11 Drinking water

• Potable water should be provided in all places of employment, for drinking, washing of the person, cooking, washing of foods, washing or cooking of eating utensils and personal service rooms.

• Drinking water dispensers should be designed, constructed and serviced so that sanitary conditions are maintained, should be capable of being closed, and should be equipped with a tap.

• Open containers, such as barrels, pails, or tanks for drinking water from which the water must be dipped or poured, whether or not they are fitted with a cover, are not sufficient.

• A common drinking cup and other common utensils are not sufficient. • Drinking station should be located at upstream of air flow in a clean area.

Example of water filter (for a small sized factory)


13.12 Toilets

• Toilet rooms separate for each gender should be provided in all places of employment.

• Toilet room should be distinctly marked “for men” and “for women” by signs printed in the native language of the persons occupying the building, or marked with easily understood pictures or symbols. If the facilities for each sex are in the same building, they should be separated by solid walls or partitions extending from floor to ceiling.

• At least one toilet bowl should be provided per 20 persons. • Where toilet rooms will be occupied by no more than one person at a time,

the rooms should be lockable from the inside. Each water-closet should occupy a separate compartment with a door and walls or partitions between and fixtures sufficiently high (1.7M for example) to assure privacy. There will be no open toilets except for urinals.

• Tightly closing waste bins should be provided within each toilet stall for used toilet paper and used sanitary dressing disposal.

• Hand drying facilities (paper towel, clean cloth towel, electric dryer or others) should be provided.

Example of a clean toilet provided with soap, paper towel and toilet paper

13.13 Canteens/Kitchen Facilities

• In all areas where central dining operations are permitted or provided, the food handling facilities should meet the requirements of all local sanitation regulations.

• Kitchen personnel must be checked for infectious diseases in regular intervals. • Refrigerator system or cold room freezer should be used and maintained at

the correct temperatures. • Seating facilities that allow for enough seating for all employees scheduled to

eat during a shift should be provided.


Example of an orderly and clean canteen

13.14 Safety signs

Safety signs should be used to:

• indicate the location of safety facilities (emergency escape or first aid sign); • warn of special dangers or hazards (warning sign); • demand a mandatory action (mandatory sign); • forbid some action (prohibition sign).

Depending on the purpose they serve, a specific color, shape and size is necessary. The European Union has set minimum requirements for the provision of health and safety signs within the directive 92/58/EEC. In this Directive it is clearly stated that

• “Employers shall provide safety and/or health signs as laid down in this directive where hazards cannot be avoided or adequately reduced …” and

• “Workers must be given suitable instruction, in particular in the form of specific directions concerning the safety and/or health signs used at work”.

Further legislation concerning health and safety signs can be found in the directive 89/391/EEC, where it is stipulated that all emergency exits and fire fighting equipment are permanently signed. For non-EU countries other legislation may be applicable.

13.14.1 Requirements for color, size and shape

• Color o Red: Prohibition sign

Dangerous behavior, danger alarm, stop, shutdown emergency cut-out devices, evacuate, fire-fighting equipment, identification and location

o Yellow or Amber: Warning Sign

Be careful, take precautions, examine

o Blue: Mandatory sign


Specific behavior or action, wear personal protective equipment • Green: Emergency escapes, first aid sign

Doors, exits, routes, equipment, facilities, no danger, return to normal

• Size and Shape

“Signboards are to be made of shock and weather-resistant material suitable for the surrounding environment” “The dimensions and colorimetric and photometric features of signboards must be such that they can be easily seen and understood”

• Fire Exit Signs

Compulsory for every floor in every factory.

(Length equals two times height)

• Fire Escape – Keep Clear Sign

• Fire Door – Keep Shut Signs To be used where a fire door was built to prevent fire from moving from one room to the other, e.g. entrance door of a chemical storage. Not to be

confused with fire exit!


• Fire Extinguisher / Hose Sign

To be used to indicate the location and purpose of Fire Extinguishers

• Fire Alarm Sign To be used to indicate the location of a Fire Alarm button

• No Smoking Sign

Compulsory in rooms where flammable chemicals are stored or other dangers of fire exist

• Flammable Chemical Sign

Compulsory for every area where highly flammable substances are used. Also containers, bottles or receptacles used for the storage of flammable chemicals must be marked.


• Chemical Storage Sign

To be used to mark the door leading to chemical storage (do not smoke, eat or drink signs may also be used)

• Classification of Hazard Signs

Compulsory to classify the danger of chemicals used or stored (must be indicated also directly on the chemicals)

Note: if one of these signs is found on the chemicals used, a safety data sheet has to be displayed in the area where the chemicals are used / stored and the instructions included in those safety data sheets have to be followed!

• Personal Protective Equipment Signs

Used to remind the worker of the PPE that should be used for different operations

• Do not Eat or Drink or Smoke Signs Used to remind the workers that no food must be consumed in a chemical storage or handling area


• First Aid Signs

Indicating the location of first aid boxes, first aid trained persons or emergency shower

• Further Warning Signs To be used where applicable

• Other useful Mandatory Signs

To be used where applicable


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14 Extreme Temperatures

Heat or cold stress is the general name for several medical conditions such as heat cramps, heat exhaustion, heat rash, heat stroke, frostbite and hypothermia. Under extreme conditions of temperature, humidity, airflow and workload, workers may experience heat or cold stress, which is the body’s attempt to maintain a normal body temperature. Factory conditions that are very hot or very cold may cause workers to suffer from a variety of heat or cold stress symptoms. Heat stroke (from extreme heat) and hypothermia (from extreme cold) are both conditions that may lead to death, if not treated immediately. Workplaces with these conditions may include casting, electroplate, rubber products factories, electrical utilities (particularly boiler rooms), laundries, chemical plants and so on. Heat Index Risk Level Protective Measures

Less than 91°F (32 °C) Lower (Caution) Basic heat safety and planning

91°F(32 °C) to 103°F(39 °C)

Moderate Implement precautions and heighten awareness

103°F(39 °C) to 115°F(46 °C)

High Additional precautions to protect workers

Greater than 115°F(46 °C) Very high to Extreme Triggers even more aggressive protective measures

The implemented procedures on safely working in extremely hot or cold temperature condition should at least include:

• Identify workplace and work assignments where a potential for heat or cold

exists.

• Satisfactory temperature control measures to eliminate or reduce risks.

• Proper personal protective equipment must be provided to workers who work

in operations involving extreme heat or cold (e.g. insulated gloves, insulated

suits, reflective clothing, or infrared reflecting face shields etc.).

• Plenty of water must be available for workers who work in areas with high

temperatures (near ovens, dryers, etc.).

• Rest breaks are frequent enough and in suitable conditions (located in warm

area if temperature conditions are extremely cold, in shaded or cooler area if

temperature conditions are extremely hot).

• Before a worker begins work in an extremely hot or cold environment, make

sure he/she has had a physical exam to determine whether he/she is fit to

work in such conditions.

• Workers who work in extremely hot or cold job should be trained to recognize

and respond to the symptoms of heat or cold stress and capable workers are

trained to provide first aid to workers showing these symptoms.

• Periodically evaluate the program to determine whether it’s effective in

preventing heat or cold stress in workers.


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The heat or cold stress prevention program needs to be established in order to reduce the risk associated with heat or cold stress including illnesses and injuries, which cover but are not limited to:

• Designating responsibilities for the program

• Water replenishment during the shift as needed

• Employee access to shade at all times for preventative recovery periods

• Responding to symptoms of possible heat or illness

• Contact provisions for emergency medical services

• Effective engineering control including ventilation, heaters, air conditioning,

cooling fans, reflective shields to redirect radiant heat and insulation

• Allow new workers to have a five-day period to adjust to extreme temperature

conditions. Similarly, give this five-day adjustment period to workers who have

been away from work for two weeks or more

• Where there is a chance that workers will suffer heat stress caused by hot

equipment, workers should wear clothing that reflects heat (aprons, jackets,

suits, etc.). Any reflective clothing should be worn loose to allow air flow

through it. Workers wearing such clothing should be careful to avoid trapping

it in machinery with

• Avoid or limit the use of alcohol and caffeine during times of extreme heat

because both dehydrate the body.

15 Auxiliary facilities/Plant (boiler, generator, forklift, elevator, air compressors)

Wherever necessary the construction, installation, operation, inspection and repair of boilers, pressure vessels, air compressor station and elevators should be carried out by competent professionals and in compliance with the local legal requirement. Boilers, generators, forklifts, elevators, and air compressors can only be maintained and operated by qualified personnel according to the requirements of the national or local law. They should be inspected by either the designated government officials or an authorized government agency at least once a year. The following safety rules should be observed when a generator is installed and operated onsite:

• Read, understand and follow the manufacturer’s instructions. • Install and Operate generator in a clean, dry and ventilated area. • Generator must be properly grounded. • After losing power, turn off main breaker or pull main fuse block. • All electrical connections must comply with the national or international

industrial standards. • Do not overload generator with too many appliances. • Use properly sized extension cords in good condition. • Only authorized personnel are allowed in the generator room


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Compressed gas cylinders are considered hazardous materials. Following guidelines are to be followed if there is any use of compressed gas cylinders at workplace:

• Flammable gas cylinders are at least 7.5m distance from open flames, hot surfaces or electric arcs.

• Storage of gas cylinder under a roof with temperature below 50°C • Protection caps on all cylinders when not actually in use. • Cylinders must be secured by acceptable means, i.e. chain, strap, or rigid

retaining bar and kept in upright position • Transport while secured on carts designed for such purposes • Back flash arresters should be in place and functioning at all times

16 Ergonomics

Ergonomics is the scientific study of human performance at work. Ergonomics considers the physical and mental capabilities of the worker and how he/she interacts with tools, equipment, work methods, tasks and the working environment. Ergonomic hazards should be controlled when designing and changing workplace or workstation with below procedures to be followed:

• Risk assessments: An assessment that identifies jobs and workstations that may contain musculoskeletal hazards, the risk factors that pose the hazards, and the causes of the risk factors

• Hazard prevention and control: Eliminating or minimizing the hazards identified in the workplace assessment by changing the job design, workstation, tools or work environment to fit the worker.

• Injury management: The effective use of available health-care resources (e.g. physiotherapy, medical) to prevent or manage work-related musculoskeletal disorders using an early intervention approach

• Training and education: A method to give both staff and supervisors an understanding of the potential risk of injuries, their causes, symptoms, prevention and treatment

Below are some common ergonomic hazards present at workplace:

• Inadequate or excessive light or glare. • Heavy, awkward or repetitive lifting, pushing or pulling • Frequent bending or twisting of the back or neck • Tasks requiring lifting either below the knees or above the shoulder. • Static postures- spending long periods without movement of a particular body

part • Working with arms above shoulder height, elbows away from the body, or

reaching behind the body. • Repetitive or prolonged grasping and holding of objects, or repetitive bending

or twisting of the wrists or elbows. • Frequent exposure to whole-body or hand-arm vibration that has not been

controlled.


• Work surfaces that require elevation of the shoulders or stooping of the back for long periods.

• Contact stress, where force is concentrated on a small area of the body.

Often, low-cost simple solutions can be used to correct these risk factors like the following:

• Make sure work surface is at the right height for the task. • Store frequently used materials, parts, or tools within easy reach and as close

to waist or hip height as possible • Use mechanical aids to move materials and products around the workplace. • Avoid extended or repeated long reaching to do work. Typically using an

awkward posture beyond 4 hours per day is considered high risk. • If possible, reduce the number of times you repeat the task or motion. • Provide seated workers with chairs of correct height with sturdy backrest, with

the feet comfortably placed on the floor. • Provide a standing chair or stool. Change work posture occasionally from

standing to sitting or vice versa. The most effective ergonomic solutions involve both the workers and management. Where local laws on ergonomics are applicable, factories are expected to comply.

16.1 Working with Elevation and Fall Hazards

Fall means a fall by a person from one level to another. Risk of a fall means a circumstance that exposes a worker while at work, or other person while at or in the vicinity of a workplace, to a risk of a fall that is reasonably likely to cause injury to the worker or other person. This includes circumstances in which the worker or other person is:

• in or on plant or a structure that is at an elevated level

• in or on plant that is being used to gain access to an elevated level

• in the vicinity of an opening through which a person could fall


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• in the vicinity of an edge over which a person could fall

• on or in the vicinity of a surface through which a person could fall

• on or near the vicinity of a slippery, sloping or unstable surface.

18.1.1. How to identify fall hazards

Identify all locations and tasks that could cause injury due to a fall. This includes access to the areas where work is to be carried out. Tasks that need particular attention are those carried out:

• on any structure or plant being constructed or installed, demolished or dismantled, inspected, tested, repaired or cleaned

• on a fragile surface (for example, cement sheeting roofs, rusty metal roofs, fibreglass sheeting roofs and skylights)

• on a potentially unstable surface (for example, areas where there is potential for ground collapse)

• using equipment to work at the elevated level (for example, when using elevating work platforms or portable ladders)

• on a sloping or slippery surface where it is difficult for people to maintain their balance (for example, on glazed tiles)

• near an unprotected open edge (for example, near incomplete stairwells) • near a hole, shaft or pit into which a worker could fall (for example, trenches,

lift shafts or service pits).

Inspect the workplace

Walk around the workplace and talk to your workers to find out where work is carried out that could result in falls. A checklist may be useful in this process. Key things to look for include:

• surfaces: o the stability, fragility or brittleness o the potential to slip, for example where surfaces are wet, polished or

glazed o the safe movement of workers where surfaces change o the strength or capability to support loads o the slope of work surfaces, for example, where they exceed 7 degrees.

• levels—where levels change and workers may be exposed to a fall from one level to another

• structures—the stability of temporary or permanent structures • the ground—the evenness and stability of the ground for safe support of

scaffolding or a work platform • the working area—whether it is crowded or cluttered • entry to and exit from the working area • edges—protection for open edges of floors, working platforms, walkways,

walls or roofs • holes, openings or excavations—which will require guarding • hand grip—places where hand grip may be lost.


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In some situations, advice may be needed from technical specialists, such as structural engineers, to check the stability of structures or load bearing capacity.

Review available information, including incident records

You should check your records of previous injuries and ‘near miss’ incidents related to falls. Information and advice about fall hazards and risks relevant to particular industries and work activities is also available from regulators, industry associations, unions, technical specialists and safety consultants.

18.1.2. How to control fall hazards

There are a number of ways to control the risks of falls. Some control measures are more effective than others. Control measures can be ranked from the highest level of protection and reliability to the lowest. This ranking is known as the hierarchy of control.

1. Can the need to work at height be avoided to eliminate the risk of a fall?

2. Can the fall be prevented by working on solid construction?

3. Can the risk of a fall be minimised by providing and maintaining a safe system

of work, including:

• providing a fall prevention device (for example, installing guard rails) if

it is reasonably practicable to do so, or

• providing a work positioning system (for example, an industrial rope

access system) if it is not reasonably practicable to provide a fall

prevention device, or

• providing a fall-arrest system, so far as it is reasonably practicable, if it

is not reasonably practicable to provide a fall prevention device or a

work positioning system.

In some cases a combination of control measures may be necessary, for example using a safety harness while working from an elevating work platform.

Whenever fall protection is needed, make sure you have the right fall-protection system, know how it works, get trained to use it – and use it. When eliminating the hazard and guardrails, or safety nets won’t work, you need personal protective equipment (PPE) – fall-restraint systems, personal fall-arrest systems. Restraint systems keep you from falling. Fall arrest systems stop falls. You will need a full-body harness if you use one of these systems. A full-body harness has straps worn around your trunk and thighs, with one or more rings in back to attach the harness to other parts of the system.

Choosing a Harness

1. Learn about the types of fall hazards on your job.

2. Make sure the harness fits you and is comfortable, to prevent body strain. You

can get shoulder and back pads to reduce harness pressure. Full-body cross-


chest harnesses are more comfortable for women and can reduce bruising

when falls are stopped.

Training

1. The employer must fit and train each worker for the equipment to be used.

2. A competent person must train workers at risk of falling about types of fall

hazards, how to protect oneself, and other hazards and limitations in using fall

protection.

**Training must cover all that can happen, like hanging in a harness and rescue. 3. If the worksite changes or the type of fall protection equipment is changed,

workers using the equipment must be retrained.

Ladder safety

1. Choose the right equipment. Use ladders mainly for climbing to or from

other levels.

2. Choose the right ladder length.

3. A sticker on a commercial ladder tells you its maximum weight capacity.

Use only type I, IA, or IAA ladders. If safety tested ladders are not

available in your locality, the employer must take responsibility for

weight capacity testing. Ladder rungs, cleats, and steps must be parallel,

level, and evenly spaced.

4. The rungs and steps of metal ladders must be grooved or roughened to

minimize slipping. Side rails must be at least 11.5 inches apart.

5. If you use two or more ladders to reach one spot, they must have a

platform or landing between them.

6. Ladder parts must be smooth to prevent punctures or cuts or snagging

of clothing.

7. Wood ladders must not be painted with a coating that can hide defects.

8. Stepladders: All four legs must be on solid, level ground. The spreaders

must be locked fully open.

9. Never climb on the cross-bracing. Never lean a stepladder against a wall.

10. Straight and extension ladders: The ladder base should be 1 foot from

the building (or top support, such as an eave) for every 4 feet of ladder

length up to the resting position. Counting rungs will give you a good

estimate of the ladder length; rungs are about 1 foot apart.

11. When working from or climbing up the ladder, keep yourself positioned

between the rails of the ladder.


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16.2 High Frequency Vibration

Regular and frequent exposure to Hand Arm Vibration can lead to permanent health effects. This is most likely when contact with a vibrating tool or work process is a regular part of a person’s job. Hand Arm Vibration can cause a range of conditions collectively known as Hand Arm Vibration Syndrome (HAVS), as well as specific diseases, such as carpal tunnel syndrome. Indentifying signs and symptoms at an early stage is important. It will allow you, as the employer, to take action to prevent the health effects from becoming serious for your employee. The symptoms include any combination of:

• Tingling and numbness in the fingers • Not being able to feel things properly • Loss of strength in the hands

Some people might experience fingers going white (blanching) and becoming red and painful on recovery, particularly in the cold and wet, and probably only in the tips at first. For some people symptoms may appear after only a few months of exposure, but for others they may take a few years. They are likely to get worse with continued exposure to vibration and may become permanent. There are hundreds of different types of hand-held power tools and equipment which can cause ill health from vibration. Some of the more common ones are: chainsaws, concrete breakers/road breakers, cut-off saws (for stone etc.), hammer drills, hand held grinders, impact wrenches, jigsaws, pedestal grinders, polishers, power hammers and chisels, powered lawn mowers, powered sanders, brush cutters. These tools or equipment can be classified as:

• Hammering device • Handheld turning tool • Fixed rotary device • Transportation vehicles

Protecting workers from the effects of vibration usually requires a combination of appropriate tool selection, the use of vibration-absorbing materials, good work practices and education programs. Here are some examples of controlling exposure to vibration:

• Use an alternative or low-vibration tool when possible. • Wear anti-vibration gloves. It also provides protection from typical industrial

hazards and from cold temperatures that, in turn, may reduce the initial sensation of white finger attacks.

• Workers can reduce the risk of hand-arm vibration syndrome (HAVS) by following work practices:

o Avoid continuous exposure by taking 10 to 15 minutes rest periods. o Rest the tool on the work piece whenever practical.


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o Refrain from using faulty tools. o Use mats with anti-vibration properties on the floor or work platform

when standing or kneeling on a vibrating surface. • Training should be conducted about the hazards of working vibrating tool

which includes: the sources of vibration exposure, early signs and symptoms of hand-arm vibration syndrome, and work practice for minimizing vibration exposure.

The American Conference of Governmental Industrial Hygienists (ACGIH) has developed Threshold Limit Values (TLVs) for vibration exposure from hand-held tools. The exposure limits are given as frequency-weighted acceleration that represents a single number measure of the vibration exposure level.

ACGIH Threshold Limit Values (TLVs) for exposure of the hand vibration in X, Y, or Z direction*

Total Daily Exposure Duration (hours) Maximum value of frequency weighted acceleration (m/s2) in any direction*

4 to less than 8 hours 4 2 to less than 4 hours 6 1 to less than 2 hours 8

Less than 1 hour 12

* Directions of axes in the three-dimensional system

17 Industrial Ventilation

Ventilation in workplaces can include both general (fresh air) ventilation and ventilation used to control airborne contamination of the workplace. General ventilation of a building is needed to satisfy the respiratory needs of its occupants and to remove any body odours and other indoor environmental contaminants. Effective and suitable provision must be made to ensure that every enclosed workplace is ventilated by a sufficient quantity of fresh or purified air. Ventilation used to control airborne contamination can be either dilution ventilation or local exhaust ventilation (LEV).

17.1 General ventilation

Enclosed workplaces should be sufficiently well ventilated so that stale air, and air which is hot or humid because of the processes or equipment in the workplace, is replaced at a reasonable rate. The air that is introduced should, as far as possible, be free from any impurity that might cause ill-health or be offensive. Air inlets should be sited away from possible contaminated air and, where necessary, filtered to remove particles. In many cases windows and doors will be sufficient. Where necessary, mechanical ventilation systems should be provided as appropriate. This is often the case when using leased facilities that may not have been originally designed for industrial or for


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specific industrial uses. However, workers should not be exposed to drafts created by these mechanisms. Re-circulating air systems should use adequate filtration to remove impurities and have some fresh air added to them before being re-circulated. Mechanical ventilation systems should be regularly and properly cleaned, tested and maintained. Where necessary for reasons of health and safety, plant failure warning devices must be provided. The fresh air supply rate should not normally fall below 5-8 litres per second, per occupant. Factors to be considered should include the floor area per person, the processes and equipment involved and whether the work is strenuous.

17.2 Dilution and local exhaust ventilation

Dilution ventilation provides a flow of air into and out of the working area and does not give any control at the source of the contaminant. The background concentration is reduced by the addition of fresh air but there is little, if any, reduction in direct exposure to the process. LEV intercepts the contaminant as soon as it is generated and directs it into a system of ducting connected to an extraction fan. To achieve the same degree of control, far less air is extracted using a LEV system than with an equivalent dilution system, with considerable cost savings. For a LEV system to be effective, each of the following components must work properly:

• A hood, enclosure or other inlet to collect and contain the contaminant close to the source of its generation.

• Ductwork, to convey the contaminant away from the source. • A filter or other air-cleaning device to remove the contaminant from the

extracted airstream. • A fan or other air-moving device to provide the necessary air flow. • Further ductwork to discharge the cleaned air to the outside atmosphere at a

suitable point. Regular maintenance/testing program should be developed and maintained to ensure the Local Exhaust Ventilation System meets expectation at workplace. Records of maintenance and testing should be kept at workplace and made available upon compliance checking.


Examples of local exhaust ventilation system.

18 Personal Protective Equipment (PPE)

Each year, a lot of workers receive disabling work-related injuries that involve the head, eyes, or feet. Personal Protective Equipment (PPE) is one defence against exposure to hazardous working conditions that can cause injury to these areas of the body. Personal protective equipment is designed to protect workers from health and safety hazards that cannot be practically removed from the work environment through engineering or administrative controls. All workers are required to use PPE whenever it is specified, or when work conditions require it. General requirements on wearing of personal protective equipment are:

• Performing a hazard assessment to select the appropriate PPE. • Personal protective equipment must meet standards established by recognized

governmental and/ or industry groups. • Train the workers in the following PPE-related areas:

o When PPE must be worn o How to wear and adjust PPE o The limitations of the PPE o The proper care, maintenance, use, and disposal of PPE

Commonly used personal protective equipment in sporting goods industry includes, but is not limited to:

• Gas masks, at work areas with harmful vapours present • Dust masks, used in the process which generates dust exposure at work • Steel Mesh gloves, to be used when using fabric cutters • Ear protector at work areas with high level of noise • Chemical resistant gloves, to be used when handling acids or caustic

chemicals • Hydrocarbon-resistant gloves when using hydrocarbon-based solvents,

cleaning agents, or chemicals. • Foot protection, to be used when handling heavy objects.


Example of cutting workers wearing steel gloves, hairnet and cotton masks at work

Careful selection and use of PPE is for everyone’s benefit and safety, so ensure that all workers take the time to know what equipment is required, and the proper procedures for its use. The inclusion of workers or workers’ representatives when deciding which PPE to purchase will increase the level of acceptance from the worker side. But remember, PPE is not a replacement for safe work practices and attention to the demands of the job; it is the last line of defense after engineering and administrative controls are proven to be ineffective at protecting employees from workplace hazards.

19 Occupational health practice

19.1 Medical care and first aid

Suitable medical facilities must be available, open and properly maintained. It is essential that the facility is kept clean and equipped to deal with any injury common to the type of factory. Proper procedures for disposal of medical waste must be followed as well. A clinic room / emergency treatment room should be made available for factories with more than 100 employees:

• The room should be clearly marked as a first aid room and a note should be

placed on the door clearly, showing the names and locations of first aiders. • An occupational nurse or physician should regularly visit the clinic room. • For larger injuries the way to the next hospital / phone number of the

ambulance must be known / displayed in the clinic room. • The room should be large enough to hold a bed / couch and the door to the

room wide enough to accommodate a stretcher, wheelchair, carrying chair or wheeled carriage. The facilities and equipment that should be provided in first aid rooms are:

o A Bed or a couch (with a waterproof surface), and frequently cleaned pillow and blankets. The number of beds should conform to requirements set out in local law.

o A chair o Clean protective garments for use by first aiders


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o A sink with running hot and cold water always available o A suitable store for first aid materials o A range of first aid equipment (at least to the standard of first aid

boxes) o Suitable, foot operated, refuse container lined with disposable plastic

bags o A bowl o Paper towels and soap o Drinking water when not available on tap, and disposable cups. o A telephone or other suitable means of communication.

• At any time during working hours (also on night shifts, if applicable), a person

qualified in first aid must be present. • The person who is to be appointed as first aider must attend training given by

a qualified organization. • First aiders should be easily identifiable. Identification can be achieved using

badges or armbands, etc • Their names, possibly with photographs, should be clearly displayed on notice-

boards. • In low risk situation, there should be at least one first aider for every 50-100

employees. • In hazardous situations there should not be less than one first aider for every

50 staff. For the smaller injuries a first aid kit should be available in every larger department and must not be locked, the contents of which must contain

sufficient quantities of items, depending again on the above circumstances. The following are recommended:

• A general guidance card with information on first aid, emergency telephone

numbers • Checklist of content • Wrapped sterile adhesive dressing • Eye pads with attachments • Wrapped triangular bandage • Safety pins • Wrapped sterile bandages • A pair of disposable gloves • Scissors • Injury Log, pen • Plaster • Disinfection liquid

A clinic record should be kept detailing types of injuries / sicknesses which occurred during the last year. In case of an unusual accumulation of injuries or any heavy injury / sicknesses reasons should be investigated and corrective actions should be taken.


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19.2 Health surveillance

Health surveillance is the periodic monitoring of the health of individual workers by a combination of medical history and examination, and relevant tests. The types of examinations and tests used will depend on the health hazard being assessed. The health surveillance program should be linked to or cover the pre-employment screen, pre-placement and post-placement examinations, and return-to-work examinations and exit health examinations. Health surveillance should be conducted if:

• required by regulations, • it is possible that worker exposure exceeds acceptable exposure limits to

hazards for which health surveillance is useful, • an employer wishes to check the health of their workforce and to see if hazard

management and control measures are effective.

If exposure has been shown to always be well below acceptable exposure limits, there is no need for health surveillance for a particular workplace hazard. Health surveillance is not a substitute for providing and maintaining adequate exposure control measures. Health surveillance should include measures and procedures to ensure that pregnant women or other identified vulnerable workers are never exposed to any hazardous conditions at work.

19.3 Structure of a health surveillance program

If health surveillance is required, the employer should establish a structured health surveillance program according to the following guidelines:

• The health surveillance program should be documented, as part of the Standard Operating Policies and Procedures.

• The health surveillance program should be based on the results of the health risk assessment.

• Workers should give their informed consent to health surveillance. • All health surveillance examinations and tests should be at no cost to the

worker. • Medical examinations and tests should be supervised by a legally qualified

physician (or nurse if appropriate). • Examinations/ tests/ laboratories should comply with international standards. • Medical examinations and tests must be safe, ethical and acceptable in

cultural and religious terms. • Tests must be valid, reliable and sensitive. • Where health surveillance detects disease, adverse health effect or unsafe

hazard exposure levels, the responsible physician or nurse should advise the employer of the need for remedial action and notify the worker of the result and its implications for him or her.

• Depending on the nature of the abnormal result and the circumstances in the workplace, the affected worker should either be suspended stating the


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expected length of unfitness, given specific restrictions, moved to a workplace that is safe for him or her, or given additional personal protective equipment.

• Workers requiring treatment for diseases found at medical surveillance should be referred to appropriate specialists for follow-up.

19.3.1 Analysis and reporting the results

A procedure should be developed and implemented for analyzing the results of the health surveillance program and providing guidance for corrective action and medical treatment. This analysis will involve looking at the results for groups of workers to identify patterns and trends across the factory. The health surveillance results should also be looked at from the perspective of the individual worker to identify clinical implications for him or her. The occupational health doctor or nurse should provide a list of employees who are fit to work and those who are not. These occupational health staff should be mindful that abnormal results on a health surveillance examination may not be due to work, but may be due to natural processes that would have happened in the absence of workplace exposure. Abnormal results may require medical follow-up outside of the factory’s occupational health service.

19.3.2 Health surveillance records

Health surveillance results should be managed as any other medical record within the occupational health service. Health surveillance results for each worker should be kept in his or her medical record, so they are available for doctors and nurses treating the employee.

20 Accidents investigation at workplace

General Introduction

An accident is an unplanned event that results in personal injury and damage to property. All accidents must be reported appropriately according to PUMA SAFE accident reporting procedures. These accidents include but are not limited to:

• fatalities (to anybody);

• a major injury (to employees);

• a person not at work (e.g. a member of the public) being taken immediately

from the scene of an accident to hospital for treatment;

• employees having more than three days off work;

• employees contracting certain diseases;

• A specific dangerous occurrence


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An accident book should be kept by employers who normally employ more than 10 people. It is important that employers make arrangements for ensuring that incidents are investigated in order to help prevent a recurrence and to provide information which can assist in improving the safety management of the company. The level of detail to which they should be investigated will vary; depending primarily upon what the consequences could have been and how likely it is that the incident will recur, rather than just upon what the consequences actually were. Employers must provide appropriate first aid equipment and facilities for employees who may suffer an injury or become ill at work. The extent to which such equipment and facilities are required will depend upon such factors as the hazards and risks employees are exposed to, the number of employees and the location of the workplace. An assessment should be carried out to determine what the first aid needs actually are. The assessment should identify whether first-aiders are required. If it is decided that they are not, employers must, as a minimum, provide ‘appointed persons’ who will take charge in the event of an injury or illness, and be responsible for the first aid equipment. Accident Investigation

As well as setting up a system to report accidents you should also ensure that arrangements are put into place to investigate their causes and take corrective action where necessary. The benefits from investigating accidents include:

• Reduced likelihood of a similar incident occurring;

• Fulfillment of statutory obligations to report the incident, where applicable;

• Development of effective monitoring procedures and assistance in decision-

making, planning and future resource allocation;

• Provision of feedback in the development of safe systems of work.

The company policy should, therefore, be to investigate: • All accidents and dangerous occurrences (an accident that resulted in a minor

injury could often have easily caused a more serious injury);

• All cases of reportable diseases;

• As many near misses as possible (a near miss incident could have been an

accident and should therefore be investigated).

This will allow the company to: • Establish the circumstances surrounding the incident;

• Draw conclusions as to the causes;

• Consider appropriate action to prevent a recurrence.


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Recording information (establishing the circumstances)

Gather as much factual information as possible early on in the investigation. This typically should include:

• the names of persons involved, including witnesses;

• the personal details of the injured person (and/or details of ill-health or

damage to plant) and the extent of the injuries/damage/ill-health;

• the type of work being performed;

• the exact location of the incident: photographs, sketches and/or plans may

prove useful;

• the time and date of the incident;

• the working conditions at the time of the incident (e.g. weather, ground

conditions, lighting, etc);

• interviews with the injured persons and witnesses: it is important that

interviews are carried out as soon as possible to ensure accuracy;

• how the incident occurred, including probable causes.

The investigation of notifiable accidents should always be carried out right after the occurrence of the accidents. Supporting material such as sketches, photographs and written statements should be attached to the accident investigation report (PS-Accident-001). While accident investigation can be a long, time-consuming procedure, in some cases a full investigation may be unnecessary, particularly where the potential for serious injury was small. It is important, therefore, that the investigator, at an early stage, obtains an indication of how detailed the investigation will need to be. This can be achieved by carrying out an assessment of the incident, which should be based on the criteria used to determine risks. This would include:

• what was the most likely severity of injury/ill-health. for example, if a person

fell from a considerable height but received only minor injuries, the

investigator should conclude that the likely injury was nevertheless at least a

major injury;

• the likelihood of a recurrence of the accident;

• the number of people who could potentially have been injured or suffered ill-

health in a similar way to the affected individual or individuals.

Completing such an assessment can help you to ensure that appropriate time and resources are devoted to the investigation, and will indicate the time-limit within which any necessary corrective actions should be completed. In addition to this specific assessment any existing risk assessments relevant to the particular activity should also be reviewed to determine whether it is still valid and to ensure that the control measures specified are adequate.


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Determining the causes of an accident

Once the necessary information has been gathered on the circumstances surrounding the incident, the investigator will then need to determine the causes. It is important to look beyond the immediate cause of an accident in order to identify the contributory and underlying causes. In general, the immediate or direct causes of accidents usually relate to:

a) An unsafe condition in the workplace such as poor housekeeping, defective

machinery, inadequate lighting, ineffective control measures; and/or

b) Unsafe acts carried out by employees such as failure to use personal

protective equipment or using unauthorized equipment, etc.

These immediate causes often arise as a result of one or more contributory or underlying causes which generally relate to the working arrangements in place and the way the organization is run, usually relating to management control. Examples include unsafe systems of work, an inadequate safety policy and a lack of training. All causes of the accidents, when identified, should be entered in the report form (PSAccident- 001 & PS-Accident-002) (see Annex for the forms) Taking appropriate corrective action

Attempt should be made to identify suitable corrective actions for all the causes identified. In some cases, it may be possible to remedy the cause immediately, such as replacing a missing machine guard, disposing of a hazardous chemical, repairing defective LEV, etc. Contributory causes, however, are likely to require more time and effort to remedy, for example:

• provision of adequate training for the injured/affected person and possibly his

colleagues;

• implementation of changes in a system of work to reduce risk to an

acceptable level;

• implementation of changes in the work process.

When it has been decided what corrective actions are required, the details should be entered in the report form (PS-Accident-001 & PS-Accident-002). The corrective actions should be completed within the time-limits recorded in the report form and when they are completed, the completion date should also be entered. It is recommended that some form of review is made of any actions taken to ensure that it has been correctly implemented and is effective.


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Circulating the results of the investigation

To obtain the full benefits of the investigation, the results should be circulated to those persons who may need to act on them and to those who might find them of interest and of use. This could include:

• managers and supervisors including not only those working in the area where

the incident occurred, but also those in other departments where similar work

processes are carried out or similar equipment used, etc;

• personnel staff including those responsible for implementing new training

arrangements and changes in job descriptions, etc;

• other relevant persons including safety representatives, safety committee

members and safety advisers, where appointed;

• PUMA Sourcing/Production management located at and or responsible for the

factory.

• PUMA.Safe Team

Training If the accident reporting and investigation procedures are to be successful, all persons involved must be competent to carry out their roles:

• employees must be informed of the reporting procedure, the location of the

accident book and how entries are made in it;

• Supervisors and managers must be informed of their roles and responsibilities

in an investigation and, if applicable, their role in accident notification under

local laws and regulations.

Suitable training must then be provided to ensure that these duties will be properly carried out. For more serious or complex incidents, a member of senior management or a safety specialist may need to be involved. During accident investigation training it is important to emphasize that the overall purpose is to establish the circumstances surrounding an accident and to identify measures that would help prevent a recurrence, not to allocate blame.

21 Workplace monitoring

Regular workplace monitoring is the critical part of every successful health and safety program. Each monitoring should include a careful examination of the workplace to identify actual and potential hazards that can cause injury, illness or damage. To ensure the effective monitoring, it is necessary to be familiar with:

• All workplace buildings and departments • Work activities and work flow from one part of your workplace to another • Where hazardous chemicals are used


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• The location of storage areas, entrances and exits, and emergency exits. Workplace monitoring must be done by local Center of Disease Control and Prevention or a qualified organization at least once a year. In addition, for any new construction, new equipment or work activities that are introduced to your workplace, an initial risk assessment and workplace monitoring should be done.

21.1 Limit of Substances Hazardous Exposure

Mostly workplace exposure limits are concentrations of the substances hazardous to health in the air averaged over a specified period of time, referred to as a time-weighted average. Two time periods are used: long term (8 hours) and short term (15 minutes). Short-term exposure limits are set to prevent acute effects which occur after exposure for a few minutes. However exposure to a substance with a workplace exposure limit must not exceed the local legal requirement.

21.2 Limit of Noise Exposure

As noise effects are cumulative, the noise emission levels should be reduced below 85 dBA. If this is not feasible they should be reduced to the lowest level possible and suitable hearing protection provided. If the noise energy is doubled, then it is increased by 3dBA and requires a halving of the exposure time, e.g.

Hours of exposure (h) dB(A) 8 85 4 88 2 91 1 94

1/2 97 1/4 100 1/8 103

• 55dB at complex office work as well as canteen and break areas • 70dB at simple office work • 85dB at all other kinds of work

Individuals exposed to 80dBA must be offered hearing protection, but at 85dBA, more hearing protection must be provided and worn. Hazard exposure of workplaces must be in compliance with local legal requirements. It is recommended that noise exposure testing for prolonged exposure (standard 8 hours) and peak exposure is done so that both types of exposure in the work stations are measured even if both may not be required by local law. Where PUMA standards are higher than local legal requirements, PUMA standards will apply. In order to control the working place hazards, a sufficient management system should be established and include at least the following:

• A description of the plan and a functional overview of the day-to-day operation. This section must contain a detailed description of this site, the location of buildings and what structures and organizations are covered by the plan.


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• Based upon the results of the evaluation/assessment survey, working place monitoring should be conducted to determine the level of exposure and potential health risk to employees.

• Employees should be trained properly. • Monitoring data should be analyzed and reviewed at regular intervals and

compared with the operating standards so that any necessary corrective actions can be taken.

22 Workplace Health Promotion

The term “workplace health promotion” is interpreted in different ways by different stakeholders. Many enterprises/organizations may be undertaking health promotion activities at the workplace without realizing they are doing so. Others may be giving priority to health promotion measures, such as promoting healthy habits, rather than to occupational safety and health practice. In recent years, health promotion programmes at the workplace are mainly being designed to assist workers in becoming more skilled in managing their chronic conditions and in becoming proactive in their health care. In line with international standards like that of the ILO, an effective workplace health promotion programme:

1. Complements occupational safety and health measures and is integrated into

the OSH management system of the organization. This way, it contributes in

establishing and maintaining a safe and healthy working environment

enhancing the quality of working life and adding to optimal physical and

mental health at work.

2. Contributes to enable workers to cope more effectively with psychosocial risks

and work-related, personal or family problems that may impact their well-

being and work performance, such as stress, violence or the abuse of alcohol

and drugs.

3. Assists workers in becoming more skilled in managing their chronic conditions

and proactive in their health care in order to improve their lifestyles, the

quality of their diet and sleep, and their physical fitness.

4. This implies that the measures taken should not only address these issues

from an individual point of view, but also from a collective one which is closely

related to the improvement of working conditions, the working environment

and work organization, as well as to family, community and social contexts.

Workplace Health Promotion (WHP) is the combined effort of employers,

workers, their communities and society to improve the health and well-being

of women and men at work.


This ecological model acknowledges that there are many factors which influence health outcomes, for example, whether and how much an individual smokes; or how they organize their diet, or how apparently similar stressful events lead to radically different consequences for different people. The increasing proportion of women in the workforce raises a range of gender-related questions about the different effects of work-related risks on men and women. Women workers are particularly disadvantaged by out of date workforce structures, workplace arrangements and attitudes. Therefore, general measures directed to all workers do not necessarily achieve the desired benefits for women workers. The concentration of women workers in the garments and footwear industries leads to a specific pattern of injury and disease. There are also different effects on women and men; exposure to hazardous substances or biological agents on reproductive health, the physical demands of heavy work, the ergonomic design of workplaces, psychosocial risks, and the length of the working day (especially when domestic duties also have to be taken into account). The response is also different, for example, women are more likely to be victims of physical violence but equally likely to be perpetrators of psychological violence; women and men have different eating and physical activity habits; women are more affected by occupational illness and men by serious accidents; there are more women in low control/high demand jobs which contribute to high levels of stress; more women than men suffer from occupational repetitive strain injuries (RSI) which are exacerbated by stress; and finally, more women than men suffer from sexual harassment at work. In applying the ecological model, the relationship between health and gender roles and between women’s health and their social and economic roles should be acknowledged. Health promotion policies incorporating the needs of working women have to take into account all three roles of women: as housewives, as mothers, and as workers. The effects on health of each of their roles have to be looked at and the potential conflicts and contradictions between them need to be considered in the design of workplace health promotion measures.

The workplace

The social environment

The

community

The

family

The

individual


The basis of a successful enterprise is the people that work in it and its organizational culture. Healthy workers in a supportive environment feel better and healthier, which in turn leads to reduced absenteeism, enhanced motivation, improved productivity, improved recruitment, reduced turnover, a positive image and a consistent corporate social responsibility. Studies in Europe on workplace health promotion show that every Euro invested yields a return on investment of € 2.5 to 4.8 in reduced absenteeism costs (BKKBV&HVBG, 1996). Other projects like HERProject implemented in India, Cambodia and China came back with similar results in terms of return on investment. Workplace health promotion programmes are an effective business investment as they can enhance and extend existing occupational safety and health programmes by contributing to keep workers fit and healthy, maintaining their ability to work and allowing them to remain active and productive members of society, while at the same time contributing to the well-being both of workers and their enterprises with more efficient and profitable working practices.

22.1 Workplace Stress

Definition of work- related stress

” People experience stress when they perceive that there is an imbalance

between the demands made of them and the resources they have

available to cope with those demands. Although the experience of stress

is psychological, stress also affects people’s physical health.”

EU, OSHA Observatory, 2009.

“Job stress can be defined as the harmful physic al and emotional

responses that occur when the requirements of the job do not match the

capabilities, resources, or needs of the worker. Job stress can lead to poor

health and even injury. ”

Stress at work, United States National Institute of Occupational Safety and Health, 1999

“By the term work related stress we mean the process that arises where

work demands of various types and combinations exceed the person’s

capacity and capability to cope. Think of this as ‘bad work’. It is a

significant cause of illness and disease and is known to be linked with

high levels of sickness absence, staff turnover and other indicators of

organizational underperformance - including human error”

HSE (Health and Safety Executive), 2010.

“Stress occurs when the perceived pressure exceeds your perceived

ability to cope”

Palmers et al, 2003


The Karasek model describes the characteristics of workers’ tasks that are associated with psychological stress. According to this model, not only the psychological demands of work lead to stress and related illnesses, but also a situation of high perceived demand, combined with low perceived control over the work process. Stress occurs when workers are prevented from responding to a stressor according to their own optimal psychological and physiological response pattern because of external factors over which they have no control. Stress at work is a result of exposure to psychosocial and organizational hazards in the workplace. In a model proposed by Palmer, Cooper and Thomas in 2001 and further applied in 2003, a number of potential hazards are linked with symptoms, outcomes and financial costs. The authors noted that the figures used in the model for costs are underestimated.

People often feel helpless in the face of stress at work. One advantage of this model is that it opens up a recognized route towards solving the problem, by using the well-established techniques of risk assessment and risk management. The model was used to create a structured stress risk assessment consisting of five steps, which linked seven key hazards to stress-related outcomes.

LOW HIGH

LOW

HIGH

Demand

Control


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Within the framework of an integrated OSH policy addressing health promotion issues, a number of strategies can be used to avoid creating stressful working conditions. Many of these are related to workload, work design and content.

• Control

• Social Support

• Matching the job and the worker

• Training and education

• Transparency and fairness

• The physical working environment

22.2 Nutrition

People’s health, their ability to work, and their moods are all influenced by the nutrition they provide for their bodies. A worker eating a balanced diet is likely to be healthier and more productive.

Culture

Change

Relationships

Support

Demands

Control

Role

E

M

P L O

Y

E E

S

Individual symptoms • Raised blood pressure

• Sleep & gastrointestinal disturbance

• Increased alcohol

and/or caffeine and/or nicotine intake

• Increased irritability & negative emotions

• Back pains; tension

• Palpitation, headaches

Organizational symptoms • Increased sickness

absence • Long hours culture

• Increased staff

performance • Reduced staff morale &

loyalty

• Increased hostility

• Coronary heart disease

• RSI • Clinical

anxiety and depression

• Burnout

• Increased overheads

• e.g. recruiting, training

• Reduced profits

• Increased

accidents • Incised

litigation

£3.75 bn

£370m

Potential Hazards Symptoms of Stress Negative Outcome

Financial Cost

1995-96

Model of Work Stress


Many people spend a large proportion of their time at work, and most of us need to eat during the working day. As what workers eat may determine how they work, it makes sense for employers to pay attention to adequate access to appropriate food. The health consequences of an imbalanced nutritional intake vary considerably, depending on whether people are eating too much, or too little, or eating the wrong proportions of macro and micronutrients and these all have an impact on work.

Not all countries require provision of food at the workplace; however by proactively providing nutritious balanced food, the spiral of negative impact can be abated.


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22.3 Other areas of workplace health promotion

A workplace health promotion program can cover the following areas:

1. Managing Workplace Violence

2. Alcohol and drugs at work

3. HIV and AIDS at work

4. Tobacco and workplace second-hand smoke

5. Physical Activity for health

6. Healthy Sleep

7. Managing the impact of economic stress

Resources to specifically manage these areas are available from the ILO, US OSHA and other international and local expert organizations.

23 Reporting to PUMA

23.1 Establishing Procedures to Report Accidents

It is essential that a system for reporting accidents in the workplace is established so that:

• An investigation can take place to prevent a recurrence;

• Statutory duties for reporting are complied with;

• Management commitment to providing a safe working environment can be

demonstrated;

• The accident is reported to the PUMA.Safe team in a timely manner.

This information serves as guidance to establishing such a procedure although the finer details of the procedure that is adopted will depend upon the size of the organization. The table on the next page details a possible procedure for accident reporting.


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Employees: Should be made responsible for reporting incidents they are

involved in to their immediate or departmental supervisor (encouragement should be given by employees/management to ensure that all accidents and as many near misses as possible are reported).

Supervisors: Should then report the incident to the appropriate manager and factory SAFE compliance officer.

Manager of SAFE Compliance officer:

Should then: 1. Ensure that the accident is reported to the appropriate

enforcing authority, if required; 2. Notify PUMA SAFE Team 3. Notify the relevant insurance company and safety

representative (where appropriate); 4. Initiate an investigation into circumstances of the

accident Timescales: This will depend on type of accident (for detailed timing

requirements of PUMA SAFE, please refer to PUMA SAFE Accident Reporting Diagram). Managers should also report accidents to enforcing authorities according to statutory requirements and to other persons as soon as practicable.

Incident/Accident Log Book

Responsibilities should be allocated for ensuring that the details of an accident are entered into the accident book (refer to PS- Accident-002.xls).

First aid: The procedure must ensure that appropriate first aid treatment is given to an injured person, and that the emergency services are contacted where necessary

Peripatetic

Workers:

The procedure must ensure that, where applicable, incidents involving peripatetic employees are reported

Serious Accidents: If the enforcing authority and/or the police become involved, they may require an accident scene to be left undisturbed until their investigations are complete (this is normally only the case where the accident is serious or potentially serious)


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PUMA SAFE Accident Reporting Diagram

First Aid/Injury/Illness (work related)

Factory keeps on file all records for PUMA SAFE Team’s review. First Aid/ Injury/ Illness are defined as medical treatment beyond first aid including restrictions of work or motion or which requires transfer to another job

Fatality work related and non work related

Factory reports fatality (death of employees) to Puma Country manager or Operation Manager immediately and reports to local PUMA SAFE team by phone and fax or email within 8 hours of the time of the accident

Lost Time accident (LTA) Medical Treatment (MT)

Restricted Work Case (RWC) (work related only)

Factory immediately reports any lost time accident to local PUMA SAFE Team by phone/fax or e-mail within 24 hours of the time of accident LTA/MT/RWC are defined as more than 24 hours of hospitalization, permanent disfigurement, loss of any member of the body , loss of consciousness, or loss of sight, unavailability back work after treatment etc.

Factory Investigations � Use Accident report (PS-

Accident-001)

� Take photos if appropriate

� Interview as appropriate

1. Employees

2. Managers

3. Union reps

4. HR

5. Relatives

6. Medical Personal

Factory Investigation � Use Accident report (PS-

Accident-001)



1. Employees

2. Managers

3. Union reps

4. HR

5. Relatives

6. Medical Personal

Factory Investigation � Use Accident report (PS-

Accident-002)



1. Employees

2. Managers

3. Union reps

4. HR

5. Relatives

6. Medical Personal

Forward to Puma SAFE Team � Send updated relevant

information to PUMA

SAFE team by email/

phone or fax

� Submit completed

Incident/ Accident

report Within 2

working days and

keep compensation

settlement record in

log

� Accident investigation

report from judicial

organ.

Forward to Puma SAFE Team � Completed accident report

within 5 working days

after occurrence

� Submit Injury/Illness log

for PUMA SAFE Team’s

review

� Where applicable keep

compensation settlement

record in log

Forward to Puma SAFE Team � Sum up and submit the

monthly accident

report to local PUMA

SAFE team before 7th

of the following

month

� Where applicable, keep

compensation

settlement record in

log

Corrective Action � Create action plan to

prevent recurrence


prevent recurrence


prevent recurrence


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Reporting Accidents Regulations relating to the reporting of injuries, diseases and dangerous occurrences usually require certain accidents to be reported to the enforcing authority (the national or local authority or in some cases the police) if they arise out of or are in connection with work activities. The reporting procedures that you may need to follow can vary according to the type of incident, national laws, local (district) regulations, etc. Listed below are examples of the types of accidents that usually have to be reported. Accidents Any accidents connected with work that result in:

• A fatality (whether or not the person involved is an employee);

• A major injury to an employee (see examples listed below);

• Any person not at work (e.g. a member of the public) being taken from the

scene of the accident to a hospital for treatment.

Examples of reportable injuries The following are typical examples of reportable injuries that are common in the HSE regulations of most countries. The list is not comprehensive as national and local variations may exist:

• Fracture of any bone, other than those in the fingers, thumbs or toes.

• Any amputation.

• Dislocation of the shoulder, hip, knee or spine.

• Loss of sight (even if only temporary).

• A penetrating injury to an eye, or a chemical or hot metal burn to an eye.

• Injury resulting from an electric shock or electric burn leading to

unconsciousness or requiring resuscitation or admittance to hospital.

• Any other injury that leads to hypothermia, heat-induced illness or

unconsciousness, requires resuscitation or requires admittance to hospital for

more than 24 hours.

• Loss of consciousness due to a lack of oxygen or exposure to a harmful

substance or biological agent.

• Acute illness requiring medical treatment or loss of consciousness which result

from the absorption of any substance into the body.

• Acute illness requiring medical treatment which is believed to be the result of

exposure to a biological agent or its toxins or infected material.

Dangerous Occurrences Any specified dangerous occurrences that have taken place (see samples of dangerous occurrences below) should be reported and investigated. In addition, if a notification has to be made directly to the enforcing authority, a written report is usually required to be sent to the enforcing authority within a specified period of time. This may vary from country to country.


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Examples of Dangerous Occurrences The following are examples of reportable dangerous occurrences that are common to many countries regulations. The list is not comprehensive as national and local variations may exist.

• Lifting machinery, etc:

o The collapse, overturning or failure of a load bearing part of a lift, hoist,

crane, derrick, mobile-powered

o Access platform, excavator, fork-lift truck, or a pile-driving frame with an

operating height of over 7 m.

• Pressure vessels:

o The failure of any closed vessel or of any associated pipe work where the

internal pressure was above or below atmospheric pressure and the failure

has the potential to cause death.

• Freight containers:

o The failure of any freight container in its load bearing parts.

• Overhead electric lines:

o Any incident in which plant or equipment comes into contact with overhead

power lines exceeding 200 volts, or causes an electrical discharge by being

in close proximity to such a line.

• Electrical short circuit:

o Electrical short circuit or overload causing fire or explosion resulting in the

stoppage of the plant involved for 24 hours or which has the potential to

cause death.

• Collapse of scaffolding:

o The collapse or partial collapse of:

� Any scaffold above 5 meters in height;

� Any scaffold erected over or adjacent to water which presents a risk of

drowning;

� The suspension arrangements of any slung or suspended scaffold which

causes a working platform or cradle to fall.

• Collapse of building or structure:

o Any unintended collapse or partial collapse of:

� Any building or structure under construction, alteration or demolition

involving a fall of more than 5 tonnes of material;

� A wall or floor in a place of work.

• Explosion or fire:

o Any explosion or fire resulting in the stoppage of plant or the suspension of

normal work for more than 24 hours.

Reportable Diseases. The enforcing authority often has to be notified as soon as possible (e.g. by express post or fax) of any occupational illness or diseases if contracted by employees as a result of their work.


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23.2 KPI Reporting

To comply with PUMA reporting requirements, the following KPIs should be measured internally and reported to PUMA upon request: These KPIs will be used by PUMA as benchmark and for PUMA’s own reporting, therefore data accuracy is important. The following chart is a guide of how a KPI can be developed. On the left side there is a general template and on the right side an example. Title of KPI: Name of the KPI

Title of KPI: Injury Rate (IR)*

*The IR allows to compare the number of injuries relative to a specific industry, within operations in a company, etc.

Dimension: Define which information is needed. How will the KPI be calculated.

Dimension: Number of injuries and illnesses per 100 full-time workers. Work hours should not include non-worked time even if it was paid (e.g. vacations, sick leave, etc.) 200,000 hours in the formula represent the equivalent of 100 employees working 40 hours per week, 50 weeks per year. Daily worked hours equal 8. IR = (Total number of injuries * 200,000) / Total number of hours worked Fatal injuries and accidents are not going to be included.

Measure: Define where the inputs are coming from (e.g. lists, reports), how often they should be generated (weekly, monthly, yearly), who should generate (department, position) and transmit them.

Measure: Obtain injuries and illness-related data from the Log of Work-Related Injuries and Illnesses, which is bi-monthly generated by the doctor and passed to HR. Work hours data is obtained from the time records and gathered from the payroll area.

Target: What exactly needs to be done (eliminate, reduce, train, improve) and when.

Target: Reduce by 50% the injury rate in 12 months.

Template for developing a KPI and example

Occupational Health and Safety KPIs:

• Injury Rate as defined by the Global Reporting Initiative (GRI)* • Lost Days due to (work related) injuries or diseases • Occupational Disease Rates (if applicable) • Fatality numbers (if applicable) • % of employees with OHS training. • % of employees covered by an OHS committee


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24 Contact

In case of any questions regarding this manual, please do not hesitate to contact your local PUMA.Safe team. Alternatively please contact: Dr. Reiner Hengstmann Global Director, PUMA.Safe Email: [email protected]


25 ANNEX

