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CHAPTER I
1. INTRODUCTION
1.1 GENERAL
Safety management system focuses on
Identify action to prevent a recurrence of an accident or
incident.
Identify action to prevent an occurrence from happening
Identify action based on trends from data of operations.
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Fig 1.1: Safety Management System
About GIL
From the Gateway of India to India‟s first indigenously designed fast breeder reactor, Gammon
has become one of the world‟s largest physical infrastructure construction companies in India,
diversified into areas including infrastructure management, transmission lines and power sector.
SMS
Safety
performance
Framework
Safety data
Risk
management
Monitoring
&assessment
Continuous
improveme
nt
Safety
accountability
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As builders to the nation, the Company makes concrete contributions by designing and
constructing bridges, ports, thermal and nuclear power station, dams, high-rise structures,
international airports, cross country water, oil and gas pipelines, highways, chemical and
fertilizer complexes and environmental structures.
Year of establishment was 1922; Mr J. C. Gammon was the driving force behind the introduction
of prestressed concrete to India. His foresight was fundamental to the company reaching its
present stature. At present Mr. Abhijit Rajan is the Chairman and Managing Director of the
Company.
1.2 NEED OF THE STUDY
Construction industry makes significant contribution to nation economy and provides large
number of employment. As per the latest statistics released by CIDC, about 31 million people are
employed in construction sector in which close to 73% are unskilled laborers. Use of new
technologies and deployment of project management strategies has made it possible for this
industry to undertake mega projects inspite of facing number of challenges. Even though it is one
of the fastest growing sectors in India, it records maximum number of accidents and injuries than
any other industrial activity. In addition to cost of human injury and death, the accidents are
unduly expensive in terms of damage of property and delays in completion of project.
Working at height is work undertaken at a place where injury could occur should somebody fall
from it (even if it is at or below ground level) - often involving the use of scaffolds, ladders,
hoists, gantries or general roof work. Falls from height are the most common cause of fatal
injury, and the second most common cause of serious occupational injuries. Many of these
accidents could have been avoided if the right equipment had been available and correct working
practices put in place. In the construction industry in the India, falls are the leading cause of
worker fatalities. Each year, on average, between 150 and 200 workers are killed and more than
100,000 are injured as a result of falls at construction sites.
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Accidents in construction of cooling tower
Five labourers died in an accident at an under-construction power plant of Korba West Power Co
Limited in Raigrah district of Chhattisgarh Saturday morning. The labourers were on a 170-foot
high scaffolding built around a cooling tower of the power plant when the scaffolding came
crashing down. The victims were buried in the debris and cranes had to be used to recover the
bodies.
The Willow Island disaster was the collapse of a cooling tower under construction at a power
station at Willow Island, West Virginia, on Thursday, April 27, 1978. The falling concrete
caused the scaffolding to collapse. 51 construction workers were killed. It is thought to be the
largest construction accident in American history.
Construction fatality rates from falling from height
Table 1.1
Country/Region Fatalities (per Annum per 100,000 Workers) Year
India 150.3 2010
France 112.1 2010
Germany 115.4 2006
Ireland 18.0 2006
Italy 114.4 2008
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United Kingdom 13.4 2009/08
United States of America 10.8 2010
The Natural Draft Cooling Tower is a very high structure and due to its height and shape carries
a lot of hazards during the construction process and has a lot of chances of accidents .Most of
the accidents are due to workers falling from height or material falling from height. Hence there
is a need for study of the hazards present during the construction of a NDCT and give their
control measures in order to minimize the risks and prevent accidents.
1.2 OBJECTIVES OF THE STUDY
To identify the hazards present in the construction of NDCT
To identify the control measures to minimize the risks
To study about the Safety Management System followed in GIL, Raipur to control the
hazards.
To give recommendation for the improvement of the safety management system
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CHAPTER 2
2. LITERATURE REVIEW
2.1 OPERATIONS OF GIL
Besides its large scale of operations in the Construction and Infrastructure domain, Gammon has
a dominant presence in energy business in which it operates in the hydro, nuclear and thermal
power sectors. Gammon‟s association with the construction of nuclear power projects dates back
to 1959 when it completed the Pre-Stresses Concrete (PSC) Ball Tank of India‟s first Atomic
Reactor Plant in Trombay. Gammon‟s projects cover businesses and projects involving
highways, public utilities, environmental engineering and marine structures. Gammon‟s expertise
also covers the design, financing, construction and operation of modern bridges, viaducts, and
metro rail, both on a Built-Operate–Transfer (BOT) basis as well as contract execution. Gammon
is also active in the Social Infrastructure sector through its operations in the realty project
segment. Examples include residential complexes such as Pebble Bay and Godrej Woods Man
Estate in Bangalore, Godrej Kalyan in Mumbai, RNA Exotica, Mumbai; Hotel complexes such
as Hotel Leela Palace, Chennai and G Staad, Bangalore besides commercial complexes such as
Galleria Mall(INXS) in Bangalore. Gammon is also currently undertaking a major project for
ISKON at Sri Mayapur in West Bengal involving the construction of a temple complex and a
modern cultural centre.
Gammon international include a majority holding in Franco Tosi Meccanica, SAE Power lines,
and Sofinter group, Italy spanning the sectors of power and industrial boilers as well as waste
and environment management systems. Gammon has received accolades and recognitions from a
variety of reputed institutions. Examples include the Indian Concrete Institute Award for most
outstanding concrete structure presented for the segmental arch bridge across the River Beas
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(Himachal Pradesh) and the first prize for „Excellent Aesthetics‟ for the Vidyasagar Sethu
Project across the River Hoogly in Kolkata.
2.2 HISTORY
The beginning of such a formidable company is to be found in the vision of an equally
formidable man. Mr. J. C. Gammon was the driving force behind the introduction of pre-stressed
concrete to India. He designed the reinforced concrete piles of the Gateway of India. The
foundations of the arch reach deep into the bedrock. With time, he came to be known as the
„Sculptor of Concrete‟.
Areas of specialization of Gammon
Transportation
Power project
Transmission and distribution
Pipelines
Structures
Irrigation projects
Ground engineering and water supply
2.3 ABOUT THE PROJECT SITE
The cooling tower project at Raipur, Chhattisgarh was given to Gammon India Ltd by GMR
energy ltd, Chhattisgarh. The project work includes construction of two cooling towers of natural
draft counter flow type. Each cooling tower shall be designed to give desired re-cooled water
temperature under design conditions for full power operation of the unit. The NDCT package
cost is 126Cr and expenditure till date is 12.6 Cr. Readiness of unit 1 NDCT is 13.06.2013 and
unit 2 is 13.10.2013.
Following are the salient features of NDCT:
No. of NDCT‟s 2Nos
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Height of NDCT 165m
Diameter of NDCT at Bottom 124m
Diameter of NDCT at Top 70m
Qty. Of Circulating Water 87000 Cum/Hr
Hot Water Inlet Temp. 42 degree C
Re-cooled water Outlet Temp. 33 degree C
Total lift = 104, Height in one lift = 1.5mts, height of rekar column =9 mts
The width of concrete of Ring Beam = 1200 mm
The width of concrete of first lift = 1080 mm
The width of concrete of 2nd lift = 967 mm
The width of concrete of 3rd lift = 850 mm
The width of concrete of 4th lift-101th lift = 275 mm
The width of concrete of 102th lift = 375mm
The width of concrete of 103rd lift = 475mm
The width of concrete of 104th lift = 600 mm
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2.3.1 GMR PLANT LAYOUT
Fig2.1: GMR plant lay out
Total Excavation Qty in NDCT –I 22000cum
Total Reinforcement Quantity in Tower Foundation 350MT
Concrete Quantity in Tower cum Foundation 3910 MT
Pond wall/Pedestal Concrete Quantity 1160 cum.
Pond Floor Excavation Quantity 39000 cum
Pond wall/Pedestal Reinforcement Quantity 504 MT
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2.3.2 MAJOR SECTIONS OF THE SITE OF GIL
Batching plant
Storage Room
Fabrication Yard
NDCT construction area
2.4THEORY OF COOLING TOWER
Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere.
Cooling towers may either use the evaporation of water to remove process heat and cool the
working fluid to near the wet-bulb air temperature or in the case of closed circuit dry cooling
towers, rely solely on air to cool the working fluid to near the dry-bulb air temperature. Common
applications include cooling the circulating water used in oil refineries, petrochemical and other
chemical plants, thermal power stations and HVAC systems for cooling buildings. Cooling
towers vary in size from small roof-top units to very large hyperboloid structures that can be up
to 200 meters tall and 100 meters in diameter, or rectangular structures that can be over 40
meters tall and 80 meters long. The hyperboloid cooling towers are often associated with nuclear
power plants, although they are also used to some extent in some large chemical and other
industrial plants. Although these large towers are very prominent, the vast majority of cooling
towers are much smaller, including many units installed on or near buildings to discharge heat
from air conditioning.
Classification of cooling towers
By build up
a) Packaged type
b) Field erected type
By heat transfer method
a) Dry cooling tower
b) Wet cooling tower
c) Closed circuit cooling tower
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By air flow generation method
1. Natural draft: Utilizes buoyancy via a tall chimney. Warm, moist air naturally rises due
to the density differential compared to the dry, cooler outside air. Warm moist air is less
dense than drier air at the same pressure. This moist air buoyancy produces an upwards
current of air through the tower.
2. Mechanical draft: Uses power-driven fan motors to force or draw air through the tower.
Induced draft: A mechanical draft tower with a fan at the discharge (at the top) which
pulls air up through the tower. The fan induces hot moist air out the discharge. This
produces low entering and high exiting air velocities, reducing the possibility of
recirculation in which discharged air flows back into the air intake. This fan/fin
arrangement is also known as draw-through.
Forced draft: A mechanical draft tower with a blower type fan at the intake. The fan
forces air into the tower, creating high entering and low exiting air velocities. The low
exiting velocity is much more susceptible to recirculation. With the fan on the air intake,
the fan is more susceptible to complications due to freezing conditions. Another
disadvantage is that a forced draft design typically requires more motor horsepower than
an equivalent induced draft design. The benefit of the forced draft design is its ability to
work with high static pressure. Such setups can be installed in more confined spaces and
even in some indoor situations. This fan/fill geometry is also known as blow through.
Fan assisted natural draft: A hybrid type that appears like a natural draft setup, though
airflow is assisted by a fan.
2.4.1 NATURAL DRAFT COOLING TOWER
For thermal power projects, the quantity of water being very large, natural draft cooling towers
are preferred; what‟s more, these are almost maintenance- free structures.
Natural draft (ND) cooling towers are majestic structures. These, in fact, have become a symbol
of power stations the world over. Their sheer size and shape make them exceptional; their design
involves considerable structural and thermo-dynamic analysis and studies. However, model
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studies need to be conducted before evolving their design and to ensure their performance. A
decrease in their efficiency from the designated range may render them unfit. During design, it
has to be stringently checked that the cooling tower is able to decrease the temperature of water
in a more-than-required quantity.
2.4.1.1 CONSTRUCTION EQUIPMENT
Cooling towers are of a large size, with a diameter in the range of a 100 m at the bottom. Their
foundations have a still larger diameter, in the range of 120 m. For such large area of
foundations, raft foundations are mostly found suitable. Only under exceptional circumstances,
as when the soil conditions are not good, are pile foundations along the periphery of cooling
towers chosen for provision. The depth of raft foundations is usually kept around 3-4 m.
Hydraulic excavators
The area of foundations being quite large and depth being 3-4 m, hydraulic excavators are most
suitable to excavate the large-sized pit to the required depth. Whenever hydraulic excavators are
used, care has to be taken to ensure that the bucket of the excavator doesn‟t cut the ground below
the required depth; otherwise, this extra cutting of soil has to be filled with concrete to provide a
solid base to foundations. In addition, tippers are required at the spot with the excavators for
transportation of excavated soil to a suitable place for its disposal.
Bar cutting and bending machines
Steel reinforcements need to be placed in the foundations, they are quite large and it is better to
use bar cutting and bending machines for this work. The same machines can later be used in
preparing the reinforcement for the cooling tower shell.
Concrete batching plant
It is generally not possible to pour the whole cooling tower raft in one pour, due to its large size.
The raft is therefore, divided into segments and poured either by supply of concrete from an
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existing concrete batching plant or by use of four or five concrete mixers for each segment.
Needle vibrators are constantly required for compaction of concrete in foundations; generally, M
20 concrete with low workability is used.
Concrete pedestals are located on the top of a circular raft for the cooling towers to provide a
solid base to the inclined columns rising at the bottom of the shell, and to create an air inlet area.
The pedestals are small structures involving around 100 cu m of concrete each; their number
varies depending upon the number of pairs of inclined columns. Each pedestal can be well
completed by using the bar bending and cutting machines for reinforcement and concrete mixers
for producing concrete. Steel formwork is used for these pedestals to minimize the leakage of
slurry.
For inclined columns
Inclined towers are the most typical component of a cooling tower, to be built with exact
precision. A slight change in their inclination alters the line of transfer of load from the shell to
the foundations and upsets calculations. The inclined columns are inclined sideways as well as to
the inside. Therefore, their layout should be done using high precision optical instruments. A
pipe scaffolding network is erected on firm ground to firmly support the shuttering for these
columns. Steel forms cutting the section in two halves are fabricated and used; these U-shaped or
semi-circular forms are easy to remove later. The forms have end flanges to be bolted in a tight
manner to make them leak-proof.
For first lift of shell
A ring beam over the inclined columns constitutes the first lift of the cooling tower shell. This
lift, in fact, acts as a starter for further laying lifts of the cooling tower shell by use of special
formwork. For the first lift, conventional scaffolding pipes and clamps are used to support the
steel shuttering and the working platform. Steel forms bent to match the true curvature of the
shell are fabricated for the inside and outside face of the shell. The ring beam for the full tower
can be laid in one go if sufficient equipment and formwork is available; in fact, it is preferable to
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lay it in one pour for a monolithic ring beam and for effective transfer of stresses. The equipment
required to lay the concrete of the ring beam run the gamut from scaffolds/staging pipes, rigid
and swivel clamps, joint pins, trough pins, base plates for pipes, vertical steel shuttering
fabricated to suit the inner and outer curvature of shell, steel plates for bottom of the ring beam,
turn buckles and side supports to keep the inner shuttering in position during pouring of concrete
and to resist concrete pressure, friction hoists to lift the buckets full of concrete to the working
platform, concrete mixers and needle vibrators, to optical instruments to check the alignment and
curvature of the ring beam and buckets and trolleys for concrete transportation.
For columns and beams
A cooling tower houses a large network of RCC columns and beams to create the supporting
structure for the cooling fills to be provided below the hot water inlet level. The level of entry of
hot water inside the cooling tower is at around 10-11 m above the ground. The cooling fill is
about 2 m below the level of its entry; thus, the fill base is about 8 to 9 m above ground level.
Adding to the depth of basin from the base of which the supporting columns are to rise, the
length of columns is in the range of 11 to 12 m. the columns are mostly rectangular in section
and erected at pre-decided locations to create a network of beams at fill level. The equipment
required in the pre-cast yard for RCC columns and beams includes steel moulds of required
sections and lengths of columns and beams, bar cutting and bending machine for preparing the
reinforcement for beams and columns, tilting type concrete mixers equipped with hoppers,
concrete carrying trolleys, needle vibrators, extra needles, curing arrangement set up including
installation of a deep bore well, provision of submersible pump, a GI pipe network for
distribution of water and hose pipes for manual sprinkling of water on the gunny bags covering
the pre-cast RCC members and mobile cranes of 10 t capacity to lift the pre-cast members from
the pre-cast yard and their unloading in the stacking cum curing yard. The cranes can be wheel-
mounted or crawler-mounted, though the latter ones are preferred. Also, low level steel trolleys
for carrying the pre-cast members from pre-cast yard to stacking yard, 25-tonne capacity trailers
for transportation of pre-cast columns and beams from the stacking yard to the inside of cooling
tower, friction hoists and manual winches for erection of RCC columns and beams inside the
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cooling towers and additional mobile cranes, (two or more), inside the cooling towers for
unloading of pre-cast members from the trailers to the ground, are required.
For shell construction
The total volume of concrete to be laid in the shell has to be worked out and the equipment
required decided accordingly. The construction of the cooling tower shell was earlier done by
conventional methods and it used to take long. These days, jump forms are used for the
construction of the shell. There is no need of removal and re-fixing of shuttering plates. These
slide up, both on the inner and outer faces, and are adjusted to suit the new inner and outer radii
of cooling tower. After the initial few lifts which require heavy concreting due to large diameter
and thickness, all further lifts can be laid in a single day, for the full periphery of the cooling
tower. This arrangement results in the construction of a 120 m high cooling tower in four to five
months, thus saving substantial time.
Jump forms
Jumpform equipment can be adjusted to suit uniform as well as variable dimensions. The
dimensions can increase or decrease as the structure is built. As the dimensions of a cooling
tower decrease up to throat level and increase thereafter, jumpform work suits it best because of
the facility it provides for adjustment to suit required parameters. Jumpform work has telescopic
railings provided on each deck to accommodate the reduction or increase in perimeter. Similarly,
the deck planks can also be adjusted. The top portion of the equipment is kept in mobile form so
that the concrete-pouring deck can be adjusted and locked in position near the periphery of the
structure. Diagonally installed spindles can adjust the form work to suit the actual profile of the
structure. Jump forms get their support for climbing from the structure itself and no scaffolding
pipe network is required to support them from the ground, nor are any layers of brackets
required, as used in conventional formwork. Anchor bolts are provided in the walls of the
structure, removed and re-fixed as the equipment rides up. Vertical rails are fixed all around the
perimeter of the structure and the equipment rides on these rails. Fixing of these rails is a
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continuous process and has to be ahead of the upward movement of the equipment. The task
seems simple but needs extra vigil to eliminate problems and bottlenecks.
Five decks
A five deck system is created in jump form work .The top deck facilitates concrete placement
and reinforcement binding work. The second deck is the main working deck for fixing shutters,
anchor bolts, form supports and sliding shutters. The work of alignment to the designed profile
of the structure, checking of parameters such as height, radius, curvature and thickness is also
carried out from this deck. The third deck allows rail extension for the upward movement of
equipment. The fourth deck is for the operation of hydraulic jacks and to ensure that the
equipment rigs are well locked in position. The fifth and last deck provides platforms for the
smooth finishing and painting of the structure. This five-tier system is provided both along the
inside as well as outside surfaces of the cooling tower.
Hydraulic system
The peripheral area of the cooling tower is divided into suitable number of segments with centre
to-centre spacing ranging from 3-8 m. Each hydraulic rig unit consists of a structural formwork
required to support the five-deck system, the shuttering form work and the hydraulic circuit. The
rig members include frames, holders, girders, longitudinal beams and bracings, handrails,
climbing rails and other steel sections and accessories. The structural framework units hang on to
the rail tracks by means of cradles. Rail tracks are fastened to the structure being built by anchor
bolts. Cradles ride up along the rails as and when the hydraulic circuit is operated, take along
with them the whole the structural framework. Each such framework carries two separate
hydraulic jacks that can be operated independently or jointly. In one stroke, the equipment rides
up by about 30 cm; each stroke hardly takes three to four minutes to operate. Power packs to
operate the hydraulic jacks are stationed on the lowermost deck. The number of jacks to be
operated by a power pack depends upon its capacity; however, it is feasible to operate 15-20
jacks through one power pack.
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Hydraulic power packs
Each power pack operates 15-20 hydraulic jacks. It is equipped with an electric motor of about
10 HP, 415 volts, 3 phase, of a reputed make like Crompton or ABB. The hydraulic pump has to
be of gear type, Bosch or some such make, with a flow capacity of 25-30 l/per minute. The
power pack should have a water cooler or heat exchanger, and oil filters in the return line. Oil
distribution and directional control valves should also be available in the pack. Oil tank of 200 l
or similar capacity should be provided.
Hydraulic hoses
The hydraulic hoses used for the transmission of hydraulic oil to the hydraulic jacks and back to
the pack should be tested under double working pressure. The bursting pressure shouldn‟t be less
than four times the working pressure. Generally, ½ inch internal diameter hoses are used. The
brand, Swastik or its equivalent should be clearly specified. The hydraulic connections should be
galvanized and tightened.
Hydraulic jacks
Hydraulic jacks used should be of double-acting type. The working pressure, cylinder inner bore
size, the stroke length, the ram diameter and the required jack capacity such as 6-10 tone, should
be worked out before providing jacks for the system. The jacks are provided both on the inner as
well as outer faces and hold the key to successful and trouble free working. A few spare jacks
should be kept at the site for replacements for leaking jacks, as such jacks refuse to take pressure
or load.
For concreting work
A tower crane should either be provided at the centre of the cooling tower for the transportation
of concrete and materials to the working deck, or diametrically opposite access towers can be
raised to facilitate concrete transportation to the top and to allow upward passage to the workers.
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A small passenger hoist can also be accommodated in these scaffolding towers. Suitable
arrangement should be made at the ground by positioning two or three mixers at each concrete
production point. The mixers can be located at ground level and provided with chutes to directly
unload the concrete in a common bucket placed over a low platform trolley moving on rails. The
trolley can be moved on the rails to the hoist point from where the buckets can be hoisted up to
the working deck. Such an arrangement can prove highly convenient and efficient.
Access towers
In case access towers are created at the site for hoisting of concrete buckets, passenger hoist and
to accommodate access ladders, huge quantities of scaffolding pipes and clamps will be required.
The length of scaffolding pipes is generally six meters, these are to be load- bearing, C class,
heavy duty, 48-60 mm in diameter, and in true plumb. Horizontal scaffolding pipes and diagonal
bracing pipes are also required. Rigid and swivel clamps are required in lakhs. Base plates for
verticals are needed to give them a wider area for dispersion of load, as are end-to-end pipe
couplers, to extend the verticals with the increase in the height of shell; two friction hoists to run
the concrete buckets to the unloading platforms created at the top and one hoist for the lifting of
materials. The hoists are to be of 5-7 tone capacity, single drum type, equipped with magnetic
brakes and use 16 mm diameter ropes. 16-22 mm diameter wire ropes are additionally required
as guide ropes for the concrete carrying buckets, as are D shackles, U-clamps, two sheave
pulleys to complete the running arrangement.
Passenger hoist
One passenger hoist is required to transport the engineers and workers to the platforms and back
to the ground level. The passenger hoist should always be of double drum type with magnetic
brakes, overload alarm and limit switches as safety guards. 22 mm diameter wire ropes should be
used to run the passenger cage. Guide ropes should keep the cage in position to avoid extra
swing or accidents. Equipment at the top deck, concrete unloading arrangements are to be
created by observing special safety measures against swaying of the buckets before tilting them
or opening their bottom flap. The scaffolding tower is to be well anchored to the completed
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portion of cooling tower and the platform receiving concrete well supported. Perforated pipes are
fixed along the outer and inner surfaces of the cooling tower to sprinkle water on the completed
portions. Booster pumps of 25 HP or so should be installed on the water tanks to lift water to
higher levels. Concrete vibrators are stationed on the working deck to fully compact the concrete
laid in the shell lifts. Plenty of spare needles should be kept available as they often need repair
and replacement during construction. Plate or form vibrators should be avoided as the work is
carried out at very high levels and high vibrations must not be allowed.
2.4.1.2Components of ND cooling tower
The following are the main components of a natural draft cooling tower:
1. Foundations
2. Cooling water basin
3. Column pedestals
4. Raker columns
5. Shell
6. Fill supporting structure
7. Fill
8. Water distribution pipe network
9. Spray nozzle network
10. Lighting system
11. Lightening protection system
12. Top platform
13. Ladders and access platforms
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Pedestrial wall Pond wall Rekar column Ring beam Footing
Fig2.2 Component of ND cooling tower
.
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CHAPTER 3
3. METHODOLOGY
3.1 GENERAL
The various procedures that are being followed to keep a check on safety at the construction
site include the following:
Safe Operating Procedure (SOP) / Methodology
HIRA (Hazard Identification and Risk Assessment) / JHA (Job Hazard Analysis)
Plant Safety Inspection
Environment Monitoring (Noise, Air & Water)
MSPR (Monthly Safety Performance Report)
Accident Investigation
Near miss and Incident reporting
Safety Committee
Safety Promotion Activity
Safety Audits as per IS
EMP (Emergency Management Plan)
Safety Alert
Traffic Management
3.2 SAFETY MANAGEMENT SYSTEM IN RAIPUR
The safety management system followed in GIL, Raipur site can be explained by the following
given procedures
Safety induction
Tool box meeting
Height pass
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Specialized training to workers
HIRAC
Safety Procedure
Safety Formats & checklist
Sub contractors, Fire Safety aspects, First Aid aspects
Incident reporting system (First Aid, Non reportable, LTA and fatal)
Accident investigation
Audits of Site & Report preparation
SRD reporting & Escalation system
Safety Committees
Safety Statics reporting to HO
MSPR
Labor camp Inspection
MOM of Site Safety Committee
Specialized training to workers
Monthly inspection and testing
3.2.1 SAFETY INDUCTION
Safety induction is given to all new staffs and workers .No staff or worker who has not been
given induction training is allowed to work at site . In the safety induction the company policy
,its objective ,its rules are explained so that each individual becomes familiar to the working
environment at site
3.2.2 TOOLBOX MEETING
Before the start of work tool box meeting is conducted where the workers all explained about the
work they have to do, the hazards present and the way to minimize the risk .It is given by the
supervisors in the presence of safety personnel and execution people. It is mandatory to conduct
tool box meeting daily otherwise the work is not allowed to start.
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Fig3.1: Tool Box meeting
3.2.3 HEIGHT PASS
In the construction field most of the work is to be done at height ,but before a worker is sent to
work at height it is ensured that he is capable to work at height .For this a competent person is
present to check the health issues of the worker and also checks whether the worker is capable to
work at height or not by acrophobia test, and no worker or staff is allowed to go to height
without showing the height pass which is given by the competent person and has to be renewed
every 6 months.
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Fig3.2: Height pass
3.2.4 SAFETY CHECKLISTS
Checklist are the other means of inspection that gives a deep understanding of technical and
other aspects of risk that may cause injury or illness. Checklists such as welding machine, cutting
machine, grinding machine and gas cutting are used in every area wherever any activity is
carrying out. Plant and machinery check lists are available and being maintained
.
GIL includes following of all the checklists:
To continually improve performance and consistency of safety, environment and
quality processes
To ensure compliance with all applicable laws
3.2.5 SUB CONTRACTORS
For sub contractors regular safety inspection, safety audits are done regularly at a particular
interval of time. Safety audit is done as per IS 14489 and based on that a report is made which
tells about where the conformities and non conformities (NC). These NC are raised to the sub-
contractor and asked to take proper action to rectify them.
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3.2.6 FIRE SAFETY ASPECTS
Fire is the rapid oxidation of a material in the exothermic chemical process of combustion,
releasing heat, light, and various reaction products. To provide guideline to ensure that proper
fire protection and prevention measures are established during execution of work all employees
are responsible for following all requirements outlined in its guideline.
3.2.7 SAFETY INSTRUCTIONS FOR PREVENTION AND FIRE PROTECTION
To prevent fire hazards, good housekeeping at all locations shall be strictly maintained.
The storage room or shed shall be of fire resistant construction.
For any Hot work jobs, Hot work permit to be obtained from concerned department.
When Hot work to be carried out at height HIRAC to be prepared and fire blanket to be
used to avoid accidental travel of sparks.
Smoking in the Office/ site premises shall be strictly prohibited.
All processes, storages, equipment‟s, plants etc. involving serious explosive and flash
fire hazard shall be located in isolated buildings where all such hazardous activities/
equipment shall be so arranged that only a minimum number of authorized employees are
exposed
In all work places having serious fire or flash fire hazards, passages between machines,
installations or piles of material shall be at least 90 cm wide. For storage piles, the
clearance between the ceiling and the top of pile should not be less than 2 meters.
Availability of sufficient quantity of fire extinguishers/ fire Buckets and Water supply at
ample pressure as per the national standards to extinguish any probable fires shall be
ensured. Portable type Fire extinguishers of class A, B, C and D shall be strategically
26
placed. .
All the firefighting equipment shall be properly maintained and inspected at regular
intervals of not less than once in a month by the responsible person and record of the
same shall be maintained.
Cylinders containing compressed gas shall never be stored near highly flammable
substances, hot processes or electrical installations.
All the firefighting equipments shall be properly maintained and inspected at regular
intervals. The portable fire extinguishers shall be tested once in a month and record of the
same is to be maintained in the form firefighting equipment inspection record. Defective
or exhausted equipment shall be replaced immediately
3.2.8 GAMMON INCIDENT REPORTING SYSTEM
3.2.8.1 INCIDENT REPORTING SYSTEM (FIRST AID, NEAR MISS REPORT)
Every incident is recorded in a register and analyzed so that lesson could be learnt. Small cut or
low level injuries are recorded in first aid register with proper sequence of how it happened. Near
misses is recorded in a defined format with total sequence of event, body part injured, corrective
and preventive action taken and management remark and sent to the HO. Incidents are also
reported to the local factory inspector and police station.
3.2.8.2 ACCIDENT INVESTIGATION
Accident investigation is done by the safety in charge/safety staff with senior execution staff at
site. Witness statements, evidences, other information is collected as to reach into the root cause
of the accident. For preventing any kind of accident a declaration sheet is filled by the safety
person after inspecting the area before doing any activity. Action plan is prepared and
implemented to prevent accident.
27
3.2.8.3 AUDIT OF SITES AND REPORT PREPARATION
The health and safety management audit adopts is a structured process of collecting independent
information on the efficiency, effectiveness and reliability of the total H&S management system
and drawing up plans for corrective action.
Internal audit, job safety analysis, SRD‟s, external audits, client‟s audit, and subcontractor audit
are some of the audit practices followed in Gammon and a report is prepared with the help of
those audits with conformities and non-conformities, so the existing system can continually be
improved. Daily inspection of whole site is done as to ensure safety by the safety officers.
Auditing examines each stages in the H&S management system by measuring compliance with
the controls the organization has developed, with the ultimate aim of assessing their effectiveness
and their validity for the future. Periodic workplace safety audits prevent injuries and accidents.
3.2.8.4 HIRAC
Before the start of any new work for eg Chipping work, Excavation , Concrete work or any
sort of such work , HIRAC(Hazard Identification and Risk Assessment and Control measures )
is prepared .The HIRAC is prepared in the presence of Execution Deptt, Safety personnel and
the work is carried out only after it is approved by the Project Manager
3.2.8.5 SAFETY ALERT
Whenever any accident or Fatality takes place in any site, Safety Alert is sent to all site
managers ,safety personnel and other staffs giving the complete description of accident, the
main cause of the accident found after the investigation , the preventive and corrective action
which should be taken in such cases. The Safety Alert is sent to all sites so that it could be
discussed in the Tool Box Meeting, and 3 Q Meeting.
28
3.2.8.6 SRD REPORTING AND ESCALATING SYSTEM
Safety Related Deficiency process is one of the important processes being included by Gammon
India in recent years. SRD (safety related deficiencies) is a very good practice followed in
gammon. In this practice safety officer visit the construction site daily and observe the safety
related deficiencies and discuss them with the site supervisor or site in engineer. Time given is
depending upon the severity of violation. If it is immediate danger to health and life the activity
is stopped on the spot. For least risk activity time is given to site in charge for compliance, if it is
not completed in the due time then SRD will be discussed with senior in charge person
consecutively. All the SRD raised in a month are discussed and reported in the MSPR
SRD 1ST
Tier
In the first tier the unsafe act or condition is being reported to the supervisor at the site and is
expected that he will close the condition within the given date
SRD 2ND
Tier
If the SRD is not closed by the supervisor within the given date than SRD is brought under the
notice of the site in charge and is expected that it will be closed by him within a given time
period.
SRD 3RD
Tier
If the SRD is not closed by the site in charge then the same will be reported in the safety
committee meeting and the same is sent to the HO
Table 3.1: Details of SRD’s
N
O
.
Details of SRD's Locatio
n Date Due date Responsible
Compl
iance
Status
Remarks
1
Long length Planks used as
flap between two rigs of
working platform
NDCT-
I 20.10.12 07.01.13
Mr.Anindy
a Dey Open
Afert 4/5 lift the issue
will comply.
29
2
Two nos. of lightening
arrester found in damaged
condition.
NDCT-
I 28.01.13 31.01.13
Mr.
B.Chetia/M
r. Anindya
Dey
Open 1st Mar'13/Mr.
B.Chetia
3
Steel bars were used for
anchoring of chain pulley
block.
NDCT-
I 28.01.13 02.02.13
Mr.Gouri
S. Bisen Open
13th Mar'13/
Mr. Anindya Dey
4
Hook latch not available of
chain pulley block which is
used for Jump form activity.
NDCT-
I 29.01.13 02.02.13
Mr.Manoj
Parmar Open
1st Mar'13/Mr. Manoj
Parmar
5
Hywa No-CG04JA/9872 &
CG04JB/3681 has no
Indicator, Reverse Hornand
no Hand brake.
NDCT-
I
29.01.13/
20.02.13
02.02.13/
22.02.13
Mr.Gouri
S.
Bisen/Anin
dya Dey
Open 1 week/
Mr. Anindya Dey
6
Distance not maintained
between empty and full gas
cylinder.
Tripath
y Fab. 29.01.13 02.02.13
Mr. Nitin
Patle Open
27th Feb'13/Mr. Nitin
Patle
7 Continuos water leakage
from water tank.
Chimne
y 29.01.13 02.02.13
Mr.
R.Borkar
Close
d
8 Hook latch not available of
tower crane.
NDCT-
II 25.01.13 06.02.13
Mr. Manoj
Parmar Open 5th March/MBP/SA
9 RCCB found not in working
condition.
Chimne
y 04.02.13 05.02.13
Mr. Daya.
Goswami Open
2nd March/Mr.
B.Chetia
1
0
Spindle speed has not
mentioned in Grinder M/c.
Chimne
y 07.02.13 09.02.13
Mr. Nitin
Patle Open 27/02/13/NP
1
1
DP test report of
30mtr,40mtr,160,200,210 &
240mtr has not submitted.
Chimne
y 07.02.13 09.02.13
Mr. Nitin
Patle
Close
d 27/02/13/NP
1
2
Landing platform has not
upto the mark @ elevation of
80 &120mtr.
Chimne
y 11.02.13 11.02.13
Mr. Rajesh
Borkar
Close
d 120mtr platform done.
1
3
Cadium has not provided of
concrete and passenger
winch.
Chimne
y 08.02.13 11.02.13
Mr.
Bhagwan
Singh
Close
d
Material not available
in store
30
1
4
Hywa operator/helper
working without safety
induction and PPE's.
Documents has not
submitted tosafety dept.
NDCT-
I 20.02.13 22.02.13
Mr.
Anindya
Dey
Open 28.02.13AD
1
5
Documents of JCB has not
submitted to safety dept.also
there is reverse horn,no
indicator.
NDCT-
I 20.02.13 20.02.13
Mr.
Anindya
Dey
Open 2DAYS/SA
1
6
JCB operator /helper
working at site without
safety induction and PPE's.
NDCT-
I 20.02.13 20.02.13
Mr.
Anindya
Dey
Close
d SA/1WEEK
1
7
Unauthorized person
operates the passenger lift of
NDCT-I.
NDCT-
I 20.02.13 21.02.13
Mr. Manoj
Parmar
Close
d 27.02.13/MBP
1
8
Test date of curve hoist has
expired.
NDCT-
I 20.02.13 22.02.13
Mr. Manoj
Parmar
Close
d 27.02.13/MBP
1
9
Hook latch not available of
15 ton hydra OR01N/2624.
NDCT-
I 20.02.13 22.02.13
Mr. Manoj
Parmar Open MBP
2
0
Third party test certificate
has not available of 15 ton
hydra OR01N/2624.
NDCT-
I 20.02.13 22.02.13
Mr. Manoj
Parmar
Close
d 27.02.13/MBP
2
1
Ordinary cutting wheel is
using for cutting of SS plate
at M/s Dharam Sai Cons.
Fabrication yard.
Chimne
y 23.02.13 24.02.13
Mr. Nitin
Patle
Close
d
31
Safety Committees
The safety committee is formed to review the implementation of safety issues and safety
requirement. Safety committee meeting is held once in a month. Safety committee is formed(as
per BOCW ACT 1996) with Project Manager as chairman, safety In charge is secretary and
Equal numbers of staff and workers are the committee members.
Fig3.3:Safety committee meeting
Safety Statistics Reporting To Ho
MSPR is send to HO in which all safety indicators are mentioned. This is method of reporting
the monthly statistic to head office about the man-hours worked, first aid cases etc
Job Name:-2X685 TPP GMR, RAIPUR
Job Code:-8945/47
32
Table3.2: Safety statistics
SL NO DESCRIPTION FTM CUMULATIVE
1 Total Safe man Hours achieved 200480 3224176
2 No. of First-Aid Cases 01 46
3 Near Miss Incidents 00 08
4 No. of LTI’s 00 00
5 No. of Fatal Accidents 00 00
6 Lost Hours due to Accidents 00 00
7 Frequency Rate [FR] 00 00
8 Severity Rate [SR] 00 00
9 Incident Rate [IR ] 00 00
10 Incidence Rate [Fatal] 00 00
11 No. of SRD’s Raised 55 872
12 No. of SRD’s Closed 50(Carry Forward 08) 859
13 No. of SRD’s Opened 13 13
14 Safety Committee Meeting 16TH
Safety Committee
meeting was held on 30th
January’13.
16
33
MSPR (Monthly Safety Performance Report)
Reporting of safety performance takes place at regular intervals. Each month, a summary of
safety performance is produced which describes the main events that have occurred during the
month, focusing on observations,SRD‟s,Inspection,Training,Near Misses. The report compares
current progress on a number of such indicators with previous years
In MSPR following things are recorded for gammon and its subcontractors. It is the monthly
safety performance briefing. It includes:
1. Safety briefing like tool box talk, 3Q meeting, motivation programs, safety competition,
awareness program, best safety performing staff/worker, induction training of
worker/staff, specialized training program, external training etc.
2. Details of manpower
3. Details of safety inspection
Number of height pass
Number of safety inspection
Medical examination
Safety committee meeting
4. HSE performance indicator(Near miss, First-Aid )
5. Man days lost
6. Frequency rate
7. Severity rate
Table3.3: MSPR report
SITE /
LOCATION GMR RAIPUR
JOB
CODE 8945/47 Month February'13
Details Of
Manpower Safety Briefing Number Attendees HSE Performance Indicators
Average No. of
HO Staff 35 Tool Box Talk 170 16239 Near Miss 1
Average No. of
LMR Staff 57 3Q Meeting 0 0
First Aid Injuries
(resumes duty instantly) 1
34
Average No. of
DMR Staff 18
Motivation/
Promotions Number Attendees
Minor Injuries
(resumes duty within 48
hours)
0
Average No. of
Voucher Staff 0
Safety
Competitions
held
NIL NIL
Loss Time Injuries
(resumes duty after 48
hours)
0
Average No. of
workers (PRW /
SC)
580
Awareness
programme
held
1 All Workers FATAL
(Loss of Life. Death) 0
Total strength at
site (Avg) 690
Name of best
safety
performer
(worker)
Mr. Kishan Karmokar
(Supv.)
Illness
(Unhealthy condition of
the person affected)
0
Total Man-hours
worked for the
month
193200
Name of best
safety
performer
(Staff)
Mr. Dilip Tiwari (Foreman
Civil)
Man Day Lost
LTI 0
Total safety staff
at site
9
(Includi
ng
Safety
Co-
ordinato
r)
SHE Trainings Number Attendees FAT
AL 0
Inspections/Audit
s
Numbe
r
Induction
Trainings
(Workers)
10 108
Frequency Rate
LTI 0
Safety Inspection 64
Induction
Trainings
(Staff)
3 3 FAT
AL 0
Audits 3
Specialized
Trainings 2 31
Severity Rate
LTI 0
Persons Medically
Examined 65
External
Trainings 0 0
FAT
AL 0
Personnel issued
height pass 65 Safety Related Deficiencies Remarks
35
Safety Committee
Meeting
17th
Safety
Commit
tee
meeting
was .
Carry forward
(last month) Raised Closed Open
Refer Attached
excel sheet
13 69 71 11
Project Manager Mr. Sunil G.Mahadik
Safety-in-
charge Mr.Rakesh Kumar
Note: 1) This MSPR report (soft copy in excel format) should reach H.O before 5th of every month.
2) signed copy of the same shall be maintained at site as Audit requirement
Labor Camp Inspection
Labor camp inspection is done once in a month and checked for cleanliness, electrical inspection
and healthy environment. Bleaching powder, mosquito spray are done in every month for the
wellness of health of workers.
Safety induction training given to the labor
Basic safety related training is given to every labor during the time of induction. This training is
compulsory for every worker before entering the job. It includes stating the company policy,
objectives and the location of Assembly points. It also includes the general guideline to the
workers before starting their job. Labors are made familiar with the safety PPE‟s that they have
to use at site and all safety precautions for different activities and general awareness.
36
Specialized training to workers
The workers doing the Technical as well as Non-Technical works are given training at regular
intervals to make them aware of the hazards and the right procedure to do their respective
works.
Fig 3.4: Grinding safety training
Monthly inspection and testing
Earthpit testing , RCCB testing and fire extinguisher inspection is done every month and a
record is maintained to check the efficiency of the same . If the result is not found up to the
standard then SRD is given to the respective In- charges
37
RCCB testing Earth Pit testing
Fire Extinguisher Inspection
Fig3.5: RCCB testing, Earth pit testing and Fire extinguisher inspection
38
MOM of site safety committee
Meeting is held once in month and following issues are discussed.
1. Client raised NC‟s
2. SRD‟s (number of SRD raised, closed, open, details)
3. Safety performance indicators (Near miss, First aid, Illness, tool box)
4. Minutes recorded(details of minute recorded, responsible person, Target date, revised
date etc )
Minutes of Meeting is prepared after a safety meeting ,which includes the topics discussed and
the tentative date by which the SRDs would be closed is also given by the incharge. An example
of MOM is attached here.
Table 3.4: MOM sample
TITLE Safety committee meeting no-17
DATE 26th
February ’13
PROJECT NO / NAME:
LOCATION
8945/47,GMR Energy Chhattisgarh Limited,
Raipur
PRESENT 27
CIRCULATION All Committee Members
SL
No
DISCUSSION Action By/Date
Compliance status
1.0 REVIEW OF LAST MOM
1.1 Plywood require for flap.
Mr. Anindya Dey assured that after
another 4/5 lift this issue will comply,
till that; planks will be fixed between
two rigs.
Continue Process
1.2 Identification no. as per test
certificate should be displayed on
all tools and tackles.
Mr. Manoj Parmar/28th
Feb‟13. Open
39
1.3 Labour colony toilets are not in
working condition.
Action plan/budget to be submitted by
Admin Dept.to Project In charge and
this issue will comply within
10th
March‟13/Mr. Vikash Saw
Open
1.4 At the time of Concrete pouring,
shed required for ground level
workers who hold the concrete
bucket at ± 0 level.
Mr. Niraj Sahu/27.02.2013 Open
1.5 Entry man (for maintain In time and
Out time register) required for
Chimney/NDCT 1 at night time.
Mr. Niraj Sahu agreed to
deploy one person for
maintaing entry register at
night time on 26th
February
2013.
For chimney Ambulance
Driver will deploy at in front
of chimney for entry those
workers who will go through
the man cage. /
Mr. R.Borkar will take this
responsibility.
If someone found without
entry then Rs:- 500/- will
impose against that person.
Continue Process
1.6 Earth pit no-3 & 4 yet not repaired
at chimney.
Mr. B. Chetia/ 1week Open
2.0 MOM for the month of February 2013
2.1 Discussion about MSPR/ Safety
Statistics.
Discussed with chairman regarding
safety statistics.
For information.
2.2 Discuss all Unattended SRD‟s.
(Attached excel sheet).
Chairman Instructed to all members to
comply the SRD‟s within the given
time period.
Ref:-Anx.no 3.0
40
2.3 Height Pass New/Renew.
(Timing should be Mon, Wed, and
Fri at 11am to 1pm)
All agreed. For NDCT-I it was
completed and for rest
it will comply within ¾
days.
2.4 No Safe access for drinking water
tank at NDCT-I.
Mr. Vikash Saw/26th
Feb’13 Closed
2.5 Drinking water testing not done. Mr. Gopal Sarda
(Admn. In Charge)/ 10.03.13
Open
2.6 Parallel work must be stopped both
at NDCT & Chimney.
No parallel work will be allowed. In
case of chimney, work may be
allowed (according to work permit) in
opposite direction of two working
platform and Section In charge will be
the responsible person for that.
Continuous Process
2.7 Sufficient PPE‟s not available at
store.
No Induction will be carried out till
purchasing of safety Shoe.
Continuous Process
2.8 Passenger vehicle drivers are
working 24hrs/day
Two drivers will deployed for both
shift for all vehicles/Mr. Vikash
Saw/27th
Feb‟13 onwards.
Continuous Process
2.9 Fire extinguisher required for
Painting work & Sai Const.
fabrication work
Mr. Vijay Pandey/ 2nd
March‟13. Open
2.10 Documents not submitted of all
TM‟s and Hand Brake, Reverse
Horn, FE, Brake Light also not
available of all TM‟s.
One by one TM will go for repair and
it will comply within 20 days/ Mr.
Abhishek Labhe.
Open
2.11 Plug top missing from max. DB‟s. Mr. Manoj Parmar/ 28th
Feb‟13. Open
2.12 Two core connection found in
many light connections.
Mr. B.Chetia/28th
Feb‟13
Open
2.13 42nd
National Safety Day
Celebration.
Budget Approved For Information
41
3.0 Unattended SRD’s
3.1 Two nos. of lightening arrester
of NDCT-I found in damaged
condition.
Fine will impose against those
respective PRW‟s and issue will
comply within 1st March‟13 by Mr.
B.Chetia.
Open
3.2 Steel bars were used for
anchoring of chain pulley block
at NDCT-I.
Wire rope sling will be used
instead of steel bars within 15 days
i.e. 13th Mar‟13 by
Mr. Anindya Dey.
Open
3.3 Hook latch not available of
Chain Pulley Block which is
used at NDCT-I.
Mr. Manoj Parmar/1st March‟13 Open
3.4 Hywa No-CG04JA/9872 &
CG04JB/3681 has no
Indicator,Reverse Hornand no
Hand brake.
Mr. Anindya Dey will responsible
for all Hywa and Earth Movers‟s
regarding all safety issues. This
issue will be closed within 1 week
otherwise work will be stopped.
Open
3.5 Distance not maintained between
empty and full gas cylinder.
Mr. Nitin Patle/27th Feb‟13 Open
3.6 Continuos water leakage from
water tank.
Mr. Vikash Saw/27th
Feb’13 Closed
3.7 Hook latch not available of
tower crane.
Mr. Manoj Parmar & Mr. Saurabh
Agrawal/ 5th March‟13.
Open
3.8 RCCB found not in working
condition.
Mr. Chetia/ 2nd
Mar‟13 Open
3.9 Spindle speed has not mentioned
in Grinder M/c.
Mr. Nitin Patle/27th Feb‟13 Open
3.10 DP test report of 30mtr,
40mtr, 160,200,210 & 240mtr
has not submitted.
Mr. Nitin Patle/27th
Feb’13 Closed
3.11 Landing platform has not up Mr. Rajesh Borkar/27th
Feb’13 Closed
42
to the mark @ elevation of 80
&120mtr.
3.12 Cadmium has not provided of
concrete and passenger winch.
Mr. Manoj Parmar/1st Mar’13 Closed
3.13 Hywa operator/helper working
without safety induction and
PPE's. Documents has not
submitted to safety dept.
Mr. Anindya Dey/28th Feb‟13 Open
3.14 Documents of JCB has not
submitted to safety dept.also
there is reverse horn,no
indicator.
Mr. Saurabh Agrawal
/28th Feb‟13.
Open
3.15 JCB operator /helper working
at site without safety induction
and PPE's.
Mr. Saurabh Agrawal
/28th
Feb’13
Closed
3.16 Unauthorized person operates
the passenger lift of NDCT-I.
Mr. Manoj Parmar
/27th
Feb’13
Closed
3.17 Test date of curve hoist has
expired.
Mr. Manoj Parmar
/27th
Feb’13
Closed
3.18 Hook latch not available of 15
ton hydra OR01N/2624.
Mr. Manoj Parmar
/1st March‟13
Open
3.19 Third party test certificate has
not available of 15 ton hydra
OR01N/2624.
Mr. Manoj Parmar
/27th
Feb’13
Closed
3.20 Ordinary cutting wheel is
using for cutting of SS plate at
M/s Dharam Sai Cons.
Fabrication yard.
Mr. Nitin Patle/27th
Feb’13 Closed
43
3.3. DETAILS OF THE HAZARDOUS ACTIVITIES AND THEIR
CONTROL MEASURES DURING THE CONSTRUCTION OF A
NATURAL DRAFT COOLING TOWER TAKEN IN GIL
The construction of a natural draft cooling tower has different hazardous activities involved in it.
Following are the activities involved, the hazards present in it and their control measures taken.
3.3.1 CONTROL OF DUST, GASES, FUMES HAZARDS
The gas cutting operation and welding works generate dangerous gases and fumes. The dust is
mainly caused in the batching plant area and frequent movement of site vehicles nearby working
zones
The measures taken in GIL Raipur are
1. Frequent and sufficient water sprinkling is arranged to prevent dust hazards at all the
access road of sites of dust prone areas
2. Dust mask is given to workers in dust prone areas
3. Face shield is given to workers involved in gas cutting and welding operation
3.3.2 EXCAVATION
The construction work starts from the excavation work. In this the soil is excavated and is taken
out by the help of hywa or dumpers. Different hazards present during this activity is as follows
Table2.1: Excavation hazards and control measures
Hazards Control measures
Excavator falls in to the pit. 1. Appointing signal man.
2. Operate machinery keeping safe distance to
avoid excavating area landslide.
3. Keep away from the excavated edge.
4.Provide barrier away from the edge of
excavation
Fall of persons into the pits 1. Provide proper ladder to get into the pits.
44
2. Maintaining housekeeping around the pit.
3. Barricade the area.
4. Provide adequate emergency access out of
excavation
Possibility of injury while swing of the bucket 1. Barricade entire excavation area
2. Workers are provided with Helmet, safety
shoes etc.
Damage to underground electrical, Telecom
cables and water services.
1. Always look for route markers.
2. Get survey details prior to start excavation
3. Make trail pits.
4. Provide warning tapes/ cable covering mats/
concrete saddles/ sand padding.
5. Use cable detectors
6. Adhere strictly to manual excavation in case
of presence of underground cables
Workers or passersby may accidentally fall
into open, unprotected excavated pits or
vehicles may accidentally be driven into an
uncovered or inadequately barricaded pit.
1. Provide guardrail systems, fences, barricades
or covers at the edge of a well, pit, shaft and
similar excavation
2. Ensure proper and adequate illumination
3. Display sign board
Collapse of sides 1. provide appropriate shoring
2. Always ensure that trenches more than 5 feet
deep (In unstable soil, trenches less than 5 feet
deep) have shoring or are laid back to a stable
slope.
3. Install shields to restrict lateral or other
hazardous movement of soil.
4. Ensure that material and equipment used for
sheeting, sheet piling, bracing, shoring and
underpinning are in good serviceable
condition.
45
5. Use timbers that are sound and free of
defects.
6. Backfill trenches as the work progresses.
7. Do not work outside of trench shields or
shoring protection in unprotected trenches.
8. Avoid jumping into or across trenches
3.3.3 PLAIN CONCRETE CEMENT
PCC is done in the base of the footing to prevent it from soil contact.
Table2.2: PCC related hazards and control measures
Hazards Control measures
Presence of Sharp stone or foreign material in
the surface,
Use of gum boot & hand gloves
Damaged or wrong shovel operation 1. Issue only appropriate tool.
2. Personnel shall know to operate the tool
3. conduct training (on job / off job)
4. Use of gum boot with steel toe.
Falling of material in deep excavated area 1. Regular daily inspection of edges.
2. Placed caution Board.
3. Use of safety helmet.
4. Restrict the area for unauthorized people
3.3.4 RAFTING
Table2.3: Rafting hazards and control measures
hazards Control measures
During the placement of steel on PCC there
can be contact / hit by rod during transfer
1. Adopt kinematic principle for manual
handling
46
/unloading of reinforcement and also there may
be fall of person due to inadequate walkway
2. Weight for more than 50 kg equipment shall
be engaged for lifting
3. Walk way should be cleared from obstacle.
4. Trade test/ competency test should be done
with all workers before assigning job
5.Lifting should be carried out proper
supervision
6. Use proper ladder or work on proper
platform
7. Training to work force who engage for
performing such activity
8. Ensure adequate supervision
9. Shoulder pad used while shifting & proper
PPE used.
10. Safety shoes, hand gloves , safety harness
11. Ensure adequate illumination at the
location
Insertion of nails and Injury due to exposed
shuttering objects
1. House keeping shall be ensured.
2. Proper PPE shall be provided
3. Tagging is used in case of exposed
shuttering object
47
Steel re-inforcement PCC column footing
Fig3.6 Rafting component
3.3.5 BATCHING PLANT
It is the plant area where the concrete mixture is prepared .It is the major section of the plant
because the concrete needed for all the construction work right from pcc to top shell is prepared
here. A lot of hazards are present in the operation of the batching plant. The hazards and their
control measures are
Table2.4: batching plant hazards and control measures
Hazards Control measures
Toppling of structure & use of unfit crane and
equipment causing fall of structure on person
causing major injury or fatal
1. Only designated cranes and loading
equipment with sufficient carrying capacity to
be used.
2. Loading, unloading and erection the plant
parts shall be done by experienced riggers
3. Ensure strict / direct supervision of a
competent person during erection of plant.
4. Lifting and erection sequence shall be done
as mentioned in the operation and Instruction
48
manual..
5. Sling's and other lifting tools used for lifting
purpose shall be tested and certified.
6. Suitable vehicle having sufficient loading
capacity shall be used for transporting the plant
parts.
7. Equipment transported on vehicle shall be
secured and tightened properly
Unguarded Moving Part resulting into
Trapping of body parts causing Multiple injury
to person
1. Before starting the plant, it shall be ensured
that nobody is working on the plant.
2. All the gears, chains & rollers of the mixers
shall be properly guard.
3. Ensure while persons are working in
conveyor line areas, the switches and controls
shall be secured and tagged so that no one can
engage them until all personnel are clear.
4. Ensure use of PPE‟s i.e. safety helmet,
gloves, safety shoes, nose mask , ear plug etc.
Emission of dust during Cement & Aggregate
Handling & Loading Can cause
respiratory/Breathing problems to workmen
1. Wet method should be used to reduce the
dust emission before loading
2. Ensure job rotation to reduce the exposure
3. Ensure use of dust mask
Due to contact with cement the Fingers/Hands
may be affected due to chemical action of
cement & sweating.
1. Training and awareness
2. Provide safety gloves to Workmen.
Irregular movements of Loaders and Tippers
may hit the workmen caused to injury/wounds
1.Ensure Reverse horn and other safety devices
to the transit mixer,
2. Ensure alarming system during enter and
exit of the transit mixer from B/ Plant,
3. Depute Signalman,
4. Restrict the area for unauthorized entry.
49
5. Ensure only trained, experienced driver,
holding a valid driving license,
6.Ensure adequate space for turning the
vehicles,
7. Ensure strict supervision,
Ensure adequate uses of PPEs such as safety
shoe, helmet and driving sit belt
Maintenance work performed by unauthorized
technician can lead to serious accident
1. Only authorized technicians shall be allowed
to carry out any repair and maintenance work.
2. Work Permit System shall be implemented
for repair and maintenance works (like, mixer
drum cleaning,
works on skip etc.)
3. During the replacement of individual parts
and large and/or heavy structural members, it
shall be
carefully attached to appropriate lifting
appliance
4. Nobody shall be allowed to stay or work
under the suspended load.
5. Ensure strict supervision during lifting
operation.
Falling of concrete at concrete batch dropping
area may cause head injury, if a person stands
at dropping area.
1.When hoppers are being loaded, personnel
should stay away from the area of falling
aggregate.
2. Restrict entering persons at dropping area by
providing necessary barricades/caution boards.
3. Ensure strict supervision
50
Fig 3.7: The batching plant of Raipur
3.3.6 GAS CUTTING OPERATION
The gas cutting operation is a very hazardous work since highly flammable gas is used for
cutting operation i.e DA (Dissolved Acetylene) and oxygen and if not properly carried out can
lead to fire
The hazards and their control measures for gas cutting operation are as follows
Table2.5 Gas cutting hazards and control measures
Hazards Control Measures
Defective Hose pipe can lead to fire and
explosion causing injury or death
1. use good quality hose pipe and leak proof
hose pipe
2. check the condition of hose in regular
interval and prior to start of work
3. Use of back fire arrester (Flash back
arrester) at both the end.
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4. Use lighting torch only for ignition purpose
In the condition of non availability of flash
back arrestor burning gas may result in
possible serious injury or lead to an fatality
1. Flashback arrestor shall be installed for the
gas to be shut off.
2. Ensure correct use and maintenance of
flashback arrestor to minimize the risk of
equipment failure from flashback.
3. All oxygen/fuel gas welding, cutting and
heating systems must be fitted with flashback
arrestors to both the regulator and blowtorch
Ends.
4. Flashback arrestors must be of the correct
type and size as recommended by the
manufacturer.
Wrong gas sequence during start-up and shut
down may lead to flash back and resulting
serious injury
1. Before lighting the blowpipe, each gas hose
should be purged separately
2. Ensure flow is freely until the operator is
sure the hose contains no impurities such as
water, dirt or blockages.
3. After purging, shut each blowpipe valve.
4. only trained and experienced person shall be
engaged for gas cutting operation
Insufficient purging to clean hoses before use
may lead to fire and major injury
This operation should take place in a well
ventilated area away from any naked flame or
ignition source
In the presence of blocked, worn, undersized or
overheated blowpipe tip there can be failure of
hoses and fittings can cause workplace fire or
explosion
1. visual inspection shall be done prior to start
gas cutting operation
2. If there are any signs of leakage, fluctuating
gas supply, gas starvation or misshapen flames,
the equipment should be shut down
3. inspection & fault correction shall be done
by maintenance team.
52
Hose run over by a vehicle during welding &
Kinked or restricted hoses can lead to fire
explosion & serious injury to personnel
1. Visual inspection shall be done prior to start
gas cutting operation.
2. Damaged hose shall be removed and
replaced immediately
Hoses of incorrect diameter & old gas hoses
can cause fire and serious injury to personnel
1. Ensure proper diameter of hose shall be in
use
2. Ensure periodic inspection of hose
3. Remove old hose which seems stiff and
brittle immediately and discard it.
Wrong gas pressures can lead to fire and
explosion
1. Ensure periodic check of all the pressure
gauges in regular interval
2. Damaged valves shall be replaced
immediately
3. If indicator shows pressure drop the machine
shall be stop and through check shall be done
Ultraviolet Radiation 1. Use face shield and proper apron.
2. Use of safety goggles as radiation intensity
3.3.7 WELDING OPERATION
Welding operation is done in the fabrication area as well as during the jump form construction
and erection of the same .It is very dangerous as it is done by the electricity . The hazards and
their control measures during the welding operation are as follows
Table 2.6 Welding operation hazards and control measures
Hazards Control Measures
Welding radiates invisible ultra violet and infra
red rays these radiation can damages the eyes
1. Use less hazardous materials such as:
Asbestos-free electrodes, gloves, and hot pads.
53
and the skin 2. Cross Ventilation shall be done to remove
harmful fumes and gases
3.Regular medical check/ monitoring of the
welders
3. Use of proper specified shielding devices
and like safety shoes without steel toe , helmet,
face shield, gloves etc.
Leakage & cuts in hoses can cause fire hazards 1. Purge regulators immediately & then turn
off.
2. Never use grease or oil on oxygen line
connections and copper fittings
3. Use the current for which the cable is
designed.
4. Use only well maintained equipment.
5. Repair or replace damaged parts before
further use.
6. ensure periodic inspection
Personnel may hit by flying particle causing
blindness and damage.
1. All persons involved with welding are
required to wear appropriate type of goggles
2. As far as possible avoid number of people
working in the area, always kept minimum
3. Follow work permit system
Welding Machine without proper earthing can
cause electrocution
1. Proper earthing shall be provided to
welding machine
2. All the connection shall be passes through
ELCB only
3. Ensure use of cable for Neutral/earth return
4. Periodic check for earthing resistance by
ELCB tester
5.Use of PPE‟ such as leather / rubber hand
gloves
54
6.Do not touch an energized electrode with
bare hands.
7. Wet working conditions should be avoided
8.Wear dry, insulated gloves in good condition
and protective clothing.
Damaged welding cable and holder can lead to
electrocution
1. Ensure use of good condition cable and
holder
2. Regular inspection for any damage
3. Ensure use of safety shoes, gum boot, hand
gloves safety helmet etc.
4. Use fully insulated electrode holders.
5. Do not use worn, damaged, undersized or
poorly spliced cables.
3.3.8 GRINDING OPERATION
The hazards present in the grinding operation and their control measures are as follows
Table 2.7 Grinding operation hazards and control measures
Hazards Control Measures
Contact with Hot Metal body can lead to burn
to personnel causing minor injury
1.Ensure that the wheels do not touch the work
rest and that the gap between wheel and rest is
no greater than 3mm.
2. Let the wheels gain maximum speed before
starting to grind.
3. Maintain proper distance while grinding
4. Use proper PPE's like hand gloves, goggles
etc.
Noise generation during operation may cause
headache ,irritation etc
1.Check that wheels are running true and are
not glazed or loaded.
2. Ensure periodic check of machine
55
3.Ensure proper oiling and lubrication
Contact with sharp edges may cause cut injury 1. Make a guard wherever sharp edge is there
or provide cushion
2. Cut the unwanted edge
3. Use apron , hand gloves, safety shoes
Wheels „run on‟ after switching off may cause
injury to personnel while come in contact with
it
1. Stand to the side of the wheels when starting
up and shut down
2. ensure no other person come near by the
machine
3. Operator shall be present at the machine till
wheel stop fully.
4.Never leave the machine running unattended
Unguarded Machine may cause crush injury
and part of body come in contact leads to
amputation
1. Ensure all guards and safety shields are in
position before starting the bench grinder.
2. Do not allow anyone to wear loose clothing
while working on bench grinder
Loose / improper connection & improper
insulation can lead to electrocution
1. Always use the double insulated portable
grinders.
2. Check electrical connection every time prior
to start work
3. Check ELCB and earth pit resistance in
regular basis
Operating low RPM wheel on high RPM
grinder can lead to breaking of wheel casing
injuries to eye and body
1. Ensure fixing of grinding wheel as per the
specifications
2. Provide guard for grinder
3.Use of safety helmet, safety goggle, hand
gloves etc.
Grinding having the larger gap in between
grinding wheel and tool rest can lead to finger
injury
1.Gap in between grinding wheel and tool rest
must not more than 3 mm
2. Ensure regular inspection
3.Use of safety goggle, safety helmet, hand
56
gloves, face shield
4.Provide guard for moving parts
Grinding with defective grinding wheel can
cause breaking of wheel causing Multiple
injury
1. Ensure use of good condition grinding wheel
2. Ensure periodic Inspection for identifying
the defective wheel.
3.Use of safety goggles, face shield, safety
helmet
3.3.9 VEHICLE SAFETY
In the construction industry the transportation work is a major activity, like transportation of
cement bags, steel, transit mixers carrying concrete mixtures, trailers carrying scraps or steel etc
holds the major importance in construction industry. Since there are a lot of vehicular activity
there are chances of accidents .The main hazards present due to vehicular movement and their
control measures are as follows
Table 2.8 Vehicle safety
Hazards Control measures
Rash driving resulting in the equipment hitting
to the personnel causing injury and death
1. Drive slowly and follow all driving rule.
2. Ensure engagement of trained and
experienced drivers/operator
3. Monitoring for the rash driving by imposing
penalty for violation.
4. Speed lock shall be done for the vehicle for
certain speed
5 Ensure the vehicle is always following
prescribed speed limit. i.e. 20 km/hr inside the
construction site.
3. Impart training for defensive driving
57
4. Speed limit boards should be displayed.
5.Speed lock shall be done for the vehicle for
certain speed
Overloading of vehicles/dumper Toppling, loss
of control over the equipment causing injury
and death
1. Ensure vehicles should be loaded as per the
loading capacity specified by the manufacturer
2. Ensure proper supervision
3. Consider condition of road before loading
the vehicle
4.Ensure use of PPE‟s for the worker/operators
i.e. safety shoes, safety helmet, reflective
jacket and seat belt etc
Inadequate space for movement for vehicles
hitting a person causing injury and death
1. Ensure adequate space for maneuvering the
equipment / vehicle
2. Provide signalman wearing reflective jacket
3. Restrict the entry for unauthorized worker
for controlling the unnecessary movement of
workforce
4. Move the vehicle in adequate space.
5.Ensure use of PPE‟s for the worker/operators
i.e. safety shoes, safety helmet, and seat belt
etc
Vehicle not having reverse horn and other
safety devices which can lead to collision with
other vehicle or person causing injury and
fatality
1. Ensure reverse horn along with other safety
devices, indicators
2. Ensure proper & timely checking of the
vehicle & preventive maintenance
3. Do not allow any vehicle without reverse
horn and safety device in site.
Extended working hours of drivers can lead to
fatigue causing injury fatality
1. Ensure no driver/operator is working beyond
the prescribed limit for working hours as per
laws
2. Ensure Job rotation for reducing fatigue
58
3. Do not allow any driver or operator for over
time.
Driving with raised tipper body near over head
line leading to electrocution causing injury or
fatality
1. Ensure / seek permission of electricity board
for power shut down
2. Maintain proper distance from over head
line
3. Install goal post arrangement to avoid
contact with over head lines
4. Provide stopper with appropriate distance
5. Operators shall be instruct not to drive with
open /raised tipper body
6. Ensure / check all the electric connection of
vehicle during maintenance
7. Deployment of trained signal man and flag
man
8. Provide flag & traffic light baton for night
hours
3.3.10 TOWER CRANE OPERATION
In the construction work most of the work is done through tower crane such as concreting work,
steel lifting, planks lifting ,jump form lifting etc. There are a lot of risks in the working of tower
crane
Table 2.9 Tower crane operation
Hazards Control measures
Improper foundation not following design 1. Foundation must be check before installation
2. Follow enabling design and construct as per
59
drawing
3.Soil condition shall be check.
4. Soil compaction shall done.
5. Installed shall be done as per drawing and
sequence shall be followed.
6.Proper communication shall be ensure.
7. Walk way should be cleared from obstacle.
8. Proper Lighting should be in provided.
10.Used proper PPE.
Electric overhead line 1. Ensure no electrical overhead line
2. All the electric line shall be shutdown
3. Permit to work system shall be followed
improper line & level maintained which can
cause injury
1.Identify the root cause for improper line
2. Keep all the workers away from surrounding
area of the tower crane.
3. Mechanical fittings should be fixed tightly.
4. All the arrangement shall be inspected by
competent person at every step.
5. Only authorized person shall be engaged.
Improper testing causing collapse of structure 1. Check the movement of crane as per the load
chart.
2.Check the movement of hook along the
boom of crane
3. During the testing of crane, ensure all the
worker away from surrounding.
4. Loading, unloading and erection the plant
parts shall be done by experienced riggers
5. Ensure strict / direct supervision of a
competent person during testing.
6. Lifting and erection sequence shall be done
as mentioned in the operation and Instruction
60
manual.
7. Sling's and other lifting tools used for lifting
purpose shall be tested and certified.
Improper balance weight loading 1. Inspection of Safe Working Load Meter.
2. Handle the loading material with Tag Line.
3. Proper counting of load weight.
4. Operation manual shall be followed
5. only competent person shall be involved
operator falling from height 1. No other person have permission in
operators cabin.
2. Cabin must have door and it should lock
after enter in cabin.
3. Safety belt should issued for the operator.
4. Give proper access to reach the cabin.
5. The condition of ladder shall be check
regularly
Following things should be inspected daily by a competent person before the start of work
1. Location of tower
2. Location of anchor blocks
3. Tower foundation
4. Erection of tower
5. Size of guy ropes
6. Verticality of tower
7. Strengthening of tower
8. Barrication around anchor blocks
9. Lifting booms & pulleys
10. Arrangement of winches, conc. Mixer
11. Access to tower
12. Protection shed for mixer & winches
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13. Signaling system
14. Temp. Lightening arrestor
15. Aviation warning signal
16. Tower / area lighting
17. Tightness of all fasteners
Ladder Mass piece Guy rope Boom Cabin
Fig3.8 Tower crane component
The main hazards in tower cranes are during
1. Erection of tower crane
2. Telescoping (fixing of mass piece to increase the height of tower crane)
3. Fixing of guy rope(for alignment)
4. Dismantling of tower crane
3.3.11 PASSENGER HOIST
Passenger lift is used to take workers and staffs to the working height .Extra maintenance should
be done and a daily inspection should be done by a competent person before it is allowed to
work. Checklist should be there in which the competent person would sign after a thorough
inspection.
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Checklist should be of following format confirming the following specification.
1. Condition of Electrical Drives
2. Condition of gear box
3. Condition of fasteners used in couplers
4. Condition of anti drop safety device
5. Condition of electromagnetic disc, thruster brake.
6. Condition of rack and pinion
7. Condition of guide roller and its lubrications
8. Structure, man cage condition
9. Function of limit switch
10. Tightness of bolts supporting pulleys
11. Availability of lift man
12. Function of signals & its switches
13. Function of emergency stop switch
14. Function of door switches
15. Alignment Check
16. Electrical cooling fan
Passenger Hoist Shed to reach passenger hoist
Fig3.9 Passenger Hoist Component
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3.3.12 JUMPFORM
The Jumpform system is hydraulically self climbing access scaffold system suitable for the
construction of RCC shell of Natural Draught Cooling Tower. The system is self climbing,
shutter panels are lifted using Air winches hence system is very efficient, effective and fast.
For the construction of a Natural Draft Cooling Tower the most important part is the Jumpform.
In any construction work above ground level, one needs access and working platform for all
activities related to field work. In a multi storied building, one gets working platforms in the
form of floor slabs at every 3.0 meters height.
For any structure like cooling tower and such other structures, where no floor slabs are
functionally required and hence not provided, access to the level of working and a work platform
for the workmen is required to be properly designed and provided. In India, till late 70‟s,
structures required were of moderate size and height were conventional, method of M.S tubular
scaffold system erected manually was found adequate but of late, in the present scenario of
achieving the benefit of economics of scale, much larger units of equipment and resulting large
sizes of civil construction units are being planned and built. Hence, conventional system of
construction had to be replaced by modern techniques, equipments and innovative methods.
The following system “JUMPFORM” of BERRUM type describes the innovative method of
providing access scaffold and platform system developed and used for the construction of very
tall structures such as Natural Draught Cooling Tower.
An assembly of two „U‟ beams with total framework and timber platforms is known as a Rig.
The rig components are assembled at ground level and erected on to the shell in an assembled
manner. The rig then takes the support from the shell already constructed and moves upwards in
lifts of 1.5 Mtr each. Thus it enables construction up to its final height.
Brief description about the system:
List of main component of Jumpform system is as follows-
1. Structural steel U beams
64
2. Inside Shutter
3. Outside Shutter
4. Shutter Bolts
5. Anchor Screws
6. Soldiers
7. Outside shutter Adjuster bolts
8. Inside shutter adjuster bolts
9. Adjustable steel pan for inside and outside shutter
10. Ladder beam
11. Air Winches
12. Temporary Shutter distance pieces
13. Support Brackets
14. Push Pull prop
15. Handrail
16. Inner Rig Post
17. Outer Rig Post
18. Hydraulic panel
19. 5 Ton capacity Jack
Brief description of unit:
Main component of Jumpform system consists of structural steel U beams of Rigs; sliding
channels anchor brackets, ladder beams, Platforms beams. One unit consists of pair of U beam
rig ,pair of sliding channels ,pair of hydraulic jacks and 6 Nos. anchors plate with 12 Nos.
anchors are to be embedded inside shell (Anchors are recoverable).
Hydraulic Device:
Hydraulic device consist of hydraulic cylinder, hydraulic panels, power pack, hydraulic hoses &
fittings.
65
1. Hydraulic cylinder:
2nos of hydraulic cylinder are fitted per rig in each side frame .Hydraulic cylinder is double
acting having stroke length of 1600mm .End mountings are clevis at head end and rod eye with
spherical bearings.
2. Hydraulic Panels:
Hydraulic panels are fixed in between the two rigs.
3. Hydraulic Power Pack:
Two power packs are provided to operate the entire rigs around the circumference of the cooling
tower.
4. Hydraulic Hoses & fittings:
This is used for the easy and fast circulation of hydraulic oil through it to the hydraulic cylinder.
Working Assembly of Jumpform:
Shutter of 1.5 m Lift ht is lifted first and then platform and Jumpform unit is lifted with the help
of jacks.
a) One unit consists of two rigs or vertical posts U beams 2.5 m center to center.
b) Maximum working distance between units is 8 m c/c .Minimum working distance between
units is 4m c/c.
c) No Jumpform part remains embedded in concrete shell .Anchor provided for fixing of
Jumpform units are taken out during working /climbing of jump form system.
d) 12 nos. anchors are required for 6 Nos. anchor plates of one unit.
e) Two through hole of 25 mm dia. is required per lift per Jumpform unit for supporting and
alignment of shutters. All these holes shall be filled with Normal cement sand.
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f) For erection of Jumpform units 4.5 m height of shell including ring beam height is required
over Raker columns.
g) Units of Jumpform system with jack and hoses are to be assembled absence of crane it shall be
lifted by tower crane. In absence of crane it shall be erected manually by chain pulley blocks /
ropes etc. Existing staging arrangement of initial ring beam supports shall be used for assembly
of Jumpform units.
h) CAT heads for dismantling of Jumpform unit‟s and lowering them at ground levels shall be
provided.
i) Self Wt. of one unit of Jumpform system structural parts is 3.5 ton (approx). Weight of timber
planks for platform is separate
Sequence of operation:
1 Fixing, Stripping and Lifting of Shutter Panels:
Fixing of shutters :
1) Insert top shutter bolts (25 dia.) from inside of shell so that bolts project past outside soldiers
enough to locate wedges
2) Tight all shutter bolts so that shutters are held in position.
3) Slide inside and outside steel pan shutters down into position.
4) Place temporary distance pieces between top of inside & outside shutters.
5) Adjust inclination of shutters to correct batter using inside & outside adjusted shutter bolts
Stripping of shutters:
Stripping of shutter panels will be start after the concrete is minimum Twelve hours old.
1) Loosen the bolts through inside shutter holding anchor screws
2) Lift inside steel PAN shutters up to Top platform.
3) Remove wedges from top shutters bolts withdraw bolts to inside of shell and tilt inside
shutters to rest against scaffold rig posts.
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4) Lift out outside steel PAN shutter up to top platform.
Lifting of shutter panels:
1) Attach Air winches to ladders beams.
2) Attach hook of air winches to the lifting U bolts on top of shutter
3) Lift the shell & hoist up so that bottom of shutters is level with top of previously concreted
lift.
4) From the inside of the shell insert shutter bolts partially into holes at top of previously
concreted lift.
5) Lower shutter on air winches to allow the shutter to rest on the bolts.
Lifting Operation of Jumpform System:
1) Rig unit is assembled at the ground level and erected on the concreted portion of 4.5 m height
along the periphery of the shell at a spacing of 8m c/c using tower crane.
2) Prior to the erection of system, brackets are fixed with anchors at 1.5 m height and frame is
erected over the brackets.
3) Shutter panels are fixed using tie bolts and concreting is started.
4) After completion of initial setting of concrete, shutter panels are lifted up.
5) Start the lifting operation of the rig using the hydraulic jack operation having stroke length is
1800mm.
6) The system will be ready for the concreting of next lift.
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Outer post Inner post
Hydraulic Ram U Beam platform extension platform support angle channel spacer
Height: 8.8 Mtr Length: 6.0 Mtr Width: 1.6 Mtr
SS Spring
Safety paul
Ms roller
wedge top
Fig3.10 component of jump form
SS Spring (16mm x 130 long) is fixed to safety paul for suspension of paul during jump form
lifting.
Safety Paul plays vital role during jumpform operation, it stops guide channel by lowering down
when hydraulic jack fails during lifting operation.
69
MS Roller is used for smooth sliding of guide channel during the lifting of jump form.
Top Wedge is idle in normal condition. It is locked in the middle bracket during lifting
operation, after giving load to the middle bracket actual process of lifting is started.
MS Wheel is fixed to the bottom of U-beam, it is touched against shell inner wall and is used for
smooth movement of rig during lifting
Wedge (Bottom) is locked in the bottom most bracket in normal condition, by locking itself to
the bottom bracket, the bottom bracket takes the whole load (vertical) of inner rig.
Channel guide
Guide channel is the most important component of jump form, hydraulic ram is fixed to top end
of channel guide, and bottom of ram to U-beam. Wedge of channel guide is locked in top most
MS Bracket. while actual lifting operation of rig, the bottom MS Bracket is relieved from load
and the whole load of rig transfers to the top bracket where channel guide is fixed. In idle mode,
hydraulic ram will be in open state, and during lifting operation, opened ram is closed and the
whole rig is lifted to the next level. There are 8 safety locks in each channel.
Channel Spacer
Channel Spacer (ISMC 150 x 75) is used to maintain a gap of 162mm for sliding of guide
channel during lifting and is fixed to inner post with U Beam
Inner post
MS Box 80x80x4mm Thk ( 02 Nos ) of length 6.82 Mtr each is connected with U Beam, and
platforms (top and middle) are connected with it. Ladder beam is also connected on top of Inner
Post.
70
Push-pull props
Push-pull props (02 Nos.) are fixed between middle and bottom platform of inner rig. The main
function of props is to level platforms of rig at various elevations of the tower as the tower
profile is hyperbolic.
Platform support angle
ISA 65 x 65 x 8mm - 04 Nos. of length 1.590 Mtr each are used for each platform, hence for 3
platforms 12 nos are required, top and middle platform supports (MS Box) are connected with
platform support angles. The lowest platform is providing working space for the hydraulic jacks
operation through a control panel operated by workmen. An assembly of two „U‟ beams with all
the total frame work and timber platforms is known as a “RIG” and is able to attend to a working
peripheral length upto 8.0 mtr.
Outer Post
Outer postof MS Box 80x80x5.4mm - 02 Nos of length 5.07 Mtr each is connected with platform
support angles of top and middle platforms. It is terminated at bottom of middle platform. Top
end of Outer Post is also connected to the ladder beam.
Bottom platform hanger
MS Tube 48.3 OD - 02 Nos of 3.9 Mtr each is connected with Outer post and bottom platform
support angles. Top end of the hanger is connected with outer post at bottom of middle platform,
and bottom end of hanger is connected to bottom platform support angles.
Platform Support
Inner Platform Support 03 nos. of MS-Box 90mm x 90mm x 365mm of length 3.168 Mtr each is
connected to the platform support angles (shell side) for top, middle & bottom platforms.
71
Outer Platform Support 03 nos. of MS-Box 90mm x 90mm x 3.65mm of length 3.096 Mtr each
is connected to the platform support angles(outer) for top, middle & bottom platforms. Distance
between top and middle platform is 2.40 Mtrs, and distance between middle and bottom platform
is 3.80 Mtrs
Hand rails
Main Handrail of MS Pipe 48.3 OD – 04 Nos, of length 3.55 Mtr each is required in inner rig.
For middle platform 01 no of handrail tube is fixed to outer post, and 01 to inner post, and for top
platform 01 no. is fixed to outer post and 01 no. is fixed to bottom platform hanger for bottom
platform. All 04 handrail tubes are fixed at the height of 1.0 Mtr from top of platform box of all
three platforms.
10 Nos. of Platform extension vertical tubes are required in inner rig.MS Pipe 48.3 OD of 1.05
Mtr length is used for platform ext. vertical tube. These tubes are welded to platform extension
box. 04 Nos each (02 for inner extensions and 02 for outer extensions) are required in middle and
bottom platform, and 02 nos (outer extension) are required in top platform.
08 nos. of Platform extension handrails are required for inner rig. MS Pipe 48.3 OD of 1.80 Mtr
length is used for platform extensions handrail. 04 nos are required in the middle platform (02
for inner extensions and 02 for outer extensions), 02 nos each are required for top and bottom
platform at outer extensions. In the total length of 1.80 Mtr, 1.5 mtr is extended along with the
platform extension , and remaining 0.30 Mtr is clamped with main handrail. Platform extension
handrail can be adjusted as required along with the platform extension.
The joint between two adjacent rigs is provided with hinged flap and thus offers lifting of
individual rigs, and continuous platform at five levels – three on working face and two on outer
side.
Brace
MS pipe of 48.3 OD is used as brace in inner rig. 02 nos. of braces of length 2.80 Mtr are used
between top and middle platform, and are connected with inner and outer post for additional
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strengthening. MS Pipe 48.3 OD of length 4.20 Mtr is used as brace between middle and bottom
platform, it is fixed diagonally between set of bottom platform hangers. This brace is also used
for additional strengthening of inner rig.
Ladders and couplers
MS Pipe 48.3 OD of length 4.88 Mtr is fabricated to form a ladder as shown in above figure, 04
nos of such ladder beams are required for one jump form.
02 nos of ladder beams are fixed to RHS inner rig posts (inner and outer post) and RHS outer rig
hanger post (inner and outer post), and 02 nos are fixed same as RHS, to LHS inner and outer rig
posts. Couplers are used for coupling the ladder beam with outer rig hanger post Ladder beam is
used to connect the outer rig with inner rig and for stacking of reinforcement. Maximum of 0.6
MT of reinforcement can be stacked on ladder beam.
Safety Tip: While picking reinforcement from ladder beam, hazard of men fall due to imbalance
is possible, and reinforcement might also fall due to improper stacking, hence PPE should be
used and reinforcement should be stacked uniformly, persons should not work under stacked
reinforcement.
Hydraulic system
Hydraulic system plays major role in jump form system. Hydraulic system is used for lifting of
rig to the upper level.
5 HP motor (1445 RPM) : 01 no.
Oil Tank (200 Ltr Cap.) : 01 no.
Directional Control Valve : 01 no.
Dial-gauge : 01 no.
Pressure regulating valve : 01 no.
Filter : 01 no.
Dowty pump (3028) : 01 no.
Oil level indicator : 01 no.
Starter : 01 no.
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One power pack of adequate capacity can serve up to 18 rigs. Two hydraulic jacks fixed on to
the rig enable lifting of the rig to required height of 1.5 M height, as maximum hydraulic ram
travel distance is 1.5 M. Thus rigs are lifted one by one, on completion of the work on the top
platforms which is used for fixing of form work & shutter.
5 HP motor with 1445 RPM is fitted on top of power pack, which enables to rotate dowty
pump for pumping of hydraulic oil.
Oil tank of 200 Ltr capacity is used for storage and supply of sufficient hydraulic oil.
Hydraulic oil of grade 68 is recommended for use.
Function of directional control valve is to direct the flow of hydraulic oil to the desired
direction to operate the control panel fitted to jumpform.
Dial guage is fitted to power pack, to display the pressure of oil. Maximum of 150 bars is
set to supply for operation.
Pressure regulating valve is used to increase/decrease the pressure of oil, and is adjusted
by looking at dial guage indicator.
Oil filter is used to filter the oil from dust and other foreign particles.
Dowty pump (3028) is fitted inside the oil tank for pumping the hydraulic oil.
Oil level indicator is made available to check the sufficient level of hydraulic oil in tank
for smooth operation of the system.
Electrical starter is used to start the motor of power pack.
Control panel
Control panel is fitted to the rig in the bottom platform for lifting operation. Every rig has
individual control panel, as the rigs are lifted individually.
Direction control valve is used for operation of the system by keeping it in operational
mode, when the lever of DC valve is kept in operational mode the oil is supplied to the
hydraulic ram, and lifting operation is done. When the lifting operation is successfully
completed, lever of DC valve is kept in non operating mode and the oil flows to the
adjacent rig for further rigs operation.
Manifold is fitted with a set of two operating levers, 01 for each hydraulic ram, these
levers are used for operating the hydraulic ram. When the DC valve is in operational
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mode, oil passes through the manifold to hydraulic ram, and when levers are operated
hydraulic ram comes into action, and lifting process is done.
Main line comes from the power pack for flow of oil, and is connected to all the control
panel for lifting operation, at junction of rigs hydraulic hose is used to connect the main
line.
Return line returns the oil to power pack after successful completion of system operation.
Oil to hydraulic ram is supplied through main line for ram operation and returned through
return line after completion of operation, two main lines and two return lines are made
available in each control panel for two hydraulic ram.
Safety net
Safety net made of PP material of size 10 Mtr x 7 Mtr (mesh size : 75 sq.mm) is fixed to inner
rig of jumpform for arresting of men and material. Top end of the net is fixed to the top platform
handrail and bottom end is fixed to inner platform box of bottom platform. Regular cleaning of
safety net is required to maintain safe environment.
Merits of jumpform
1) This system avoids erection of scaffolding framework manually and helps to achieve very
safe construction.
2) The system does not need skilled labour and time for erection of scaffold up to the full
working height and also saves on labour and time required for its dismantling and
lowering to ground level.
3) This system on adaptation has resulted in considerable saving of construction time of
N.D Cooling Tower. The time taken for a cooling tower with conventional method used
to be double the time of the present system adopted, i.e jump form.
4) From safety point of view this system is considered to be the safest as it is providing 5
platforms (i.e 03 on the inner side and 02 on outer) throughout the circumference and has
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sufficient working space, and safety net is provided on inner and outer rig resulting safe
working atmosphere.
5) At any circumstance, if jump form collapses, it does not come to ground as ladder beam
rests on the RCC shell.
Top platform used for shutter lifting
Middle platform used for concreting work Bottom platform used for finishing work
Fig 3.11 Components of jump form
The hazards and their control measures for jumpform erection are as follows
Table2.10:Jumpform erection hazards and control measures
Hazards Control measures
Cut while contact with sharp
edges of jump form parts
1. Sharp edges shall be protected
2. Only trained person shall be allowed
3. Ensure training given to engaged person
4. Ensure implementation of PPE's like cut resistant hand
gloves, safety shoes, helmet.
Fall & Slip of Spanner 1. Material should be placed properly
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2. Engage trained workmen to execute the job.
3. Ensure safety net to catch fall of material.
Tripping due to peripheral
material
1. Ensure & maintain good housekeeping
2. All the material should be placed at the designated area.
Fall of whole assembly causing
fatal accidents
1. only tested & certified crane allowed for performing the task
2. Competent & certified crane operator should be engaged
3. Trained signal man engaged
4. Inspect the crane prior to start the work.
5. All the lifting tools and tackles must be checked and tested
e.g. D-shackles & slings etc.
6. Ensure unauthorized entry.
7. Ensure no person work under during assembly.
8. Ensure strict / proper supervision.
Improper placement of material
/ fall of loose material
1. Ensure all nut & bolts tighten properly before lifting whole
assembly.
2. Ensure designated area identified for storage of loose
material.
3. Ensure no one allowed to work below assembly area.
4. Ensure good house keeping
Failure of slings, d-shackles 1. Ensure all the slings & d-shackles shall be tested by certified
agency
2. Ensure inspection shall be done before start of work
Fall of person due improper
fixing of & anchoring
1. Ensure use of full body harness by all the person.
2. Ensure correct fixing / anchoring of point or life line rope.
3. Provide temporary working platform ad fixed properly from
both the side
4. Provide life line rope.
5. Ensure hand railing & foot railing
6. Only trained workmen engaged to execute the job.
7. Work should be done under supervision.
8. Hand Railing & foot railing will be provided on the jump
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form frame.
Jump form activities
Table2.11: Jumform activities
Do’s Don’ts
1. Do use sound planks for all working
platforms of Jump form.
2. Do daily housekeeping of all working plat
forms.
3. Do provide Top rail, mid rail & Toe guards
on JF plat forms.
4. Do use of good quality of safety nets for
inner & outer side plat forms.
5. Do daily inspection of JFs.
6. Do use of walky-talky for communication
between shell & ground
supervisor/engineer.
7. Use suitable PPE‟s like safety helmet,
Shoe, Safety Harness/belt etc.
8. Use RCCB/ELCB for all Distribution
boards on Jump Form.
9. Deploy experienced workers for Jump
form, shell concreting, shuttering & steel
fixing related activities.
10. Do inspect all lifting tools & tackles by
competent person before putting in use.
1. Do not leave openings in the plat form.
2. Do not use damaged planks for plat forms.
3. Do not use local & damaged safety nets for
Plat form JFs.
4. Do not sleep on the platform.
5. Do not store overload steel on ladder beams
of jump form.
6. Do not store loose steel on the ladder
beams.
7. Do not leave any openings without safety
net.
8. Do not horseplay on the working platforms.
9. Do not pull overloaded safety nets at the
time of cleaning, call for coworkers to pull
overloaded safety net.
10. Do not allow inexperienced for height
work.
11. Do not use damaged tools & tackles.
12. Do not start cleaning of working plat forms
of jump forms without communicating with
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11. Tie safety nets correctly in the junction of
two jump forms.
12. Provide 18mm flap of plywood between
the two jump forms with hinges.
13. Depute personnel to restrict the entry of
personnel in the restricted area.
14. Provide wooden boxes on the platforms to
store all loose materials & kept all loose
material in the provided wooden boxes.
15. Fill the gap between platform & shell with
the provision of 8mm steel mesh.
16. Check the effectiveness of safety latch,
safety springs before starting the jump
form lifting activity.
17. Provide cover all safety springs from
falling concrete for its long life &
effectively.
18. Anchor safety harness with lifelines.
19. Do use of right tools for right job.
20. Do cleaning of safety nets regularly.
21. Barricade all internal & outer periphery
area of NDCT.
22. Do use of ladders for getting up & down.
23. Do use of correct/good conditioned chain
pulley block for shuttering lifting.
24. Tie all pan shutters correctly to prevent
ground supervisors.
13. Doesn‟t use damage PPE‟s.
14. Do not lift Jump form without Safety latch
& bracket springs.
15. Do not work by drinking.
16. Do not allow parallel working (working on
the ground & work at height).
17. Do not allow to work at height without
valid height pass.
18. Do not run on the working platforms.
19. Do not store any loose material on the
working platform.
20. Do not throw any material from the height.
21. Do not use short cuts to getting up & down
from top platform to bottom platform.
22. Do not accumulate debris on the shuttering
plates.
23. Do not use platform planks to provide
support below the shuttering plate.
24. Do not leave half lifted shuttering plates.
25. Do not walk on the steel reinforcement
bundle which stored on the ladder beams.
26. Do not do any hot work on the jump form
without permission.
27. Do not put steel reinforcement vertically on
the working platforms of jump forms.
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falling from height.
25. Anchor chain pulley correctly with the
shuttering plate.
26. Follow instructions of works supervisors.
27. Do inform all near misses/incidents to
works supervisors on the time.
28. Do inform of any unsafe condition/act to
works supervisors.
28. Do not stand on the jump forms at the time
of lifting except jump form lifting
personnel.
29. Do not try to operate fire extinguisher
without valid reason.
30. Do not try to operate/handle any electrical
connection without electricians.
CHAPTER 4
4. RESULT AND DISCUSSION
4.1 Good practices followed in GIL Raipur site to prevent accidents
1) In each vehicle it is mandatory to have reverse horn, break light, hand brake ,rear view
mirror etc. also the vehicle must have PUC(pollution under control) certificate. A vehicle
without these things is not allowed to enter the site .
2) The condition of the platforms in jumpform are continuously monitored and if found in a
condition not suitable for work ,no workers are allowed to work on it unless the needful
is done
3) The jumpform are kept cleaned and housekeeping is done daily to prevent accumulation
of debris on it .
4) No one is allowed to go at height if he is not having Height Pass, despite of the fact
whether he is staff of GIL or Client
5) The height pass is renewed after every 6 months
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6) No minor worker or a mentally retarded person or person suffering from any disease is
allowed to work and is rejected during the induction training
7) No drunk worker is allowed to enter the work site and Heavy penalty is imposed to the
sub- contractor if his worker is found working after consuming alcohol.
8) The hydra is not allowed to work if not having limit switch, hook latch, reverse horn ,
load indicator .
9) The curve hoist for passenger should have third party testing certificate ,Limit switch,
emergency stop switch, alarm bell, fire extinguisher.
10) All RCCB, and earth pit resistance are inspected every month and a record is kept for the
same .
11) Mobile shed for the surveyors is given so that they can work while the work is going on
on the shell
12) No parallel work is allowed ,i.e if work is going on the shell than no one is allowed to
work under it on the ground level.
13) Tool box is done daily by the supervisors in the presence of safety personnel and daily
record is kept for the same .
14) Specialized training is given to the workers according to their job frequently
15) A lot of posters are displayed in the working are to encourage and motivate workers to
work safely
16) Prizes are given to individual workers and to the PRWs practicing safety in the working
area to motivate others workers to follow the safe working methods
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CHAPTER 5
5. SUMMARY AND CONCLUSION
The work is in progress and measures to prevent accidents are taken . Guidelines of safety
measures like checklists, work permit and other formats given by Gammon are implemented
GIL Raipur follows the best safety procedures and complies with all the safety rules and
regulation and complies with the standards of NBC and other standards which is proved by
the fact that the site has achieved the milestone of 3 million safe man hours, which also
proves that the efficiency of Safety Management System followed in Raipur .
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CHAPTER-6
RECOMMENDATION
Although the milestone of 3 million safe man hours has been achieved but there is always a
scope of improvement in the safety measures taken and the safety management system
implemented.
1. More safety audits has to be done to i.e every week there has to be a audit to find if the
safety measures taken are meeting the standards.
2. Since the most hazardous activity is the jumpform whether it is erection ,dismantling or
working on it , more training programes should be conducted to train every workers
3. Fire extinguishers has to be installed on the platforms of the jumpform or sand buckets
should be kept .i.e at least 2 fire extinguisher should be installed on each platform since
the planks and the flaps used are made of wood and can catch fire easily as welding
works are also done .
4. The platforms should be kept clean of debris and other unwanted materials i.e proper
housekeeping has to be carried out .
5. Continuous curing has to be done during the concreting works so that the waste concrete
should not form big lumps of debris
6. The safety nets should be cleaned every week and proper maintenance has to be done .
7. Proper size of Grittings should be placed in the gaps between the shell and the jumpform.
8. Every day before the start of work maintenance people should check the condition of the
jumpform and the platforms and only after they give assurance the work should be started
since after every jumpform lift there are some issues like gaps between shell and
platform, flaps between two platforms, hand railing and other issues should be solved
before the start of work
9. All the workers need to be trained to work on the platform , for eg how many people can
stand on a single platform, how much steel can be kept on each platform
10. In many industries workers meeting with accidents with vehicles while resting under or
behind it is a common, in order to prevent such accident “Delay Start Time” should be
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installed in all vehicles , i.e when the driver will start the engine ,loud alarm noise in the
form of horn will start which will make the worker who is resting to run and only after
the set delay time i.e 1 or 2 minutes the vehicle will start and move
11. Accident in batching plant is also common so Delay Start Time can be be installed to
prevent the accidents.
12. No vehicles without reverse horn, rear view mirror, helper shall be allowed to enter the
site to work
13. Awareness programes should be conducted regularly
14. Motivational activities like competition and prize distribution should be conducted to
motivate the workers.
15. All the workers should be trained to operate the fire extinguishers and for that more mock
drills should be there..
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REFERENCES
1. Gammon India Limited Data.
2. Behm M, 2005, Linking Construction Fatalities to the Design for Construction Safety
Concept, Safety Science, Number 43, Pages 589-611
3. Churcher D W, Alwani-Starr G M,Incorporating construction health and safety into the
construction”, Implementation of Health and Safety in Construction Sites, Alvels, Dias
& Coble (eds), ISBN 90-5410-847-9, 2006
4. ECI 2000 Safety and Health, Proceedings of the ECI/CIB/HSE international
Conference, London, European Construction Institute, Lough boroughed A G F Gibb,
June 245pp ECI, Publications
5. Gambatese JA, Hinze J and Haas C, Tool to Construction Worker Safety, Journal of
Architectural Engineering, Volume 3, 2010
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ANNEXTURE
