Presentation on Safety in Construction Prakash Nirwan 28

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

Contents of the Presentation Pack • Background & Importance of Safety in Construction • Project details for 6 Mtpa at Tata Steel, KPO • Tata Steel’s initiatives in Construction Safety 2

Importance of Construction Projects The Construction industry is an important indicator of the development: • Creates investment opportunities across various related sectors • Contributes in Economy Growth (Approx. 10 % in Developing Countries' GNP) • Major Employment Generator At the same time it is also associated with proportionately high number of job-related accidents due to: • Labour intensive nature • Continuously changing working environments • Involvement of several different agencies • Custom of employing migrant farm labour from lower-wage economies for short term 3

Importance of Construction Projects Thus addressing Construction Safety Performance and the safety of the workers in the construction industries can have a great impact on: • Reducing injuries • Cost associated with safety • Project delays 4

Challenges of Construction Industry in India Cultural Gaps Unorganised Sector Socio. Economic Problems Competent Manpower Environmental Impact assessment Construction Activities Labour Camps Safety Awareness Social Hazards at Site 5 Source: Godrej : Safety Control in Construction Industry Training Infrastructure

Study Result of 1996 in UK shows…. 1. The construction industry had: 15 victims per 1, 000 workers as compared to 4 per 1, 000 workers in all other industries combined 2. The frequency of disabling injuries in construction industry 5300 per 1, 000 as compared to 3100 per 1, 000 in all other industries “The records of the last 45 years confirm the trend that the Construction Industry has VERY high fatalites and injury rates. ” 6 Source: European Journal of Scientific Research

Accident Statistics during Construction Helander (1991) in examined 739 construction deaths that occurred in the UK based on the following categories used for classifying fatal accidents : 7 Source: European Journal of Scientific Research

Key Factors in Accident Prevention Based on Model Survey analysis, the Six Most Important factors in Accident Prevention are: 1. Maintaining Safe Work Conditions 2. Establishing Safety Training 3. Safety Education to support good safety habits amongst workers and supervisors 4. Effective Control of the main contractors on site 5. Maintaining Close Supervision of all work 6. Assigning Safety Responsibility to all levels of management and workers 8 Source: European Journal of Scientific Research

Key findings of study on Accident Prevention Study focusing on Middle Level Management found that: • Management attitudes have more influence on Safety than the foreman or peer groups • Workers work more Safely for a supervisor who respects his men and their contribution • Better co-ordination improves Safety • Work on piece rate basis rather than a fixed hourly basis increase the probability of accidents 9 Source: European Journal of Scientific Research

Contents of the Presentation Pack • Background & Importance of Safety in Construction • Project details for 6 Mtpa at Tata Steel, KPO • Tata Steel’s initiatives in Construction Safety 10

MOU Signing Between Tata Steel and Govt. of Odisha on 17 th November’ 04 11

Location in Kalinganagar Industrial Complex Jakhapura Rly Station Rohit F/A VISA Plot-1 Plot-2 Jindal Stainless Tata Steel MESCO BRPL NINL 12

KPO: Major Facilities & Capacity Major Production Units Raw material handling system Coke oven by-product plant: 4 Batteries Sinter plant Pellet plant Blast Furnace Lime Calcining Plant Steel Melt Shop Hot Strip Mill Cold Rolling Mill Captive Power Plants: -By-product Gas Based -Coal based 13 Capacity/Size 19 mtpa raw materials 2. 8 mtpa Gross Coke 496 sqm 4. 25 mtpa 2 x 4300 cu m 3 x 600 tpd 6 mtpa slab 5. 5 mtpa 2. 2 mtpa 3 x 67. 5 MW 3 x 150 MW

Contents of the Presentation Pack • Background & Importance of Safety in Construction • Project details for 6 Mtpa at Tata Steel, KPO • Tata Steel’s initiatives in Construction Safety 14

Challenges in Green Field Project • Lack of Industry Culture (Safety Knowledge & commitment) • High proportion of unskilled & temporary workmen • Transient nature of contract workers during construction activities (Frequent Work Team rotations) • Exposure to weather conditions (Extreme Hot, stormy) • Indiscipline (Personal Behaviour) • Societal issues (Intoxication habits) 15 humid &

Safety Management System at Tata Steel Apex Safety Committee Training & Communi cation Safety Standard Incident Analysis Observa tion & Audit OHS Process Safety Contract or Mgmt. Road & Rail Safety Positive Isolation Rules and Procedure PSRM Sectional Implementation Committees (@ 50) 16 Training and Communication Area Implementation Committees (20) OHS & Environment Road and Rail Logistic Observati on & Audit Incident Analysis Construction and Contractor Management Divisional Implementation Committee : KPO

Safety Organization Focus Areas (Du. Pont Methodology to achieve World Class Standards) A) Line Management Accountability & Responsibility B) Construction & Contractor Safety Management C) Process Safety Risk Management D) Rules, Procedures & Performance Standards E) Positive Isolation F) Safety Observation and Audit G) Incident Investigation & Analysis H) Road & Rail Safety I) Occupational Health & Environment J) Training & Communication K) Consequence Management & Motivation 17

World Steel Survey-Critical areas(based on Fatal) FY 11 80% of these causes are applicable in construction phase Total 120 Nos. 18

Action Plan: Material Handling & Working at Height Activity / Process Material Falling / Material Handling Hazards associated Means to address Hazard Monitoring & control of overloading of trucks, dumpers etc. Issue of Height Pass based on medical test Isolating work place under working at height like bracket, D-Shackles, turn buckles as per Transportation Safety Standard Adherence to Barrication Standard at excavated Fall from pits height, Working platforms, life line, Use of double lan. Working at Injury due yard harness, fall arrestor and safety net Height to falling Compliance to Scaffolding Standard 19 Fool Fail Safe Fail Soft Proof Crush, Toe guards to scaffolding (for arresting material impact, hit falling from height) injury Practice of chain lashing with necessary fixtures objects Measures

Chain lashing with fixtures during transportation 20

Fail Soft: Working Platform & Lifeline Working Platform and Lifeline 23/05/12 21 23/05/12

Use of Safety Nets during Structure Erection Use of Safety Nets 22

Working at Height : Safe Soft Methodology Use of Full Body Harness and Double Lanyards 23

Compliance Monitoring of Scaffolding Safety Visual Display of Scaffolding Checking Status 24

Safe Access for working at height 25

Material Handling using Tower Cranes 26

Action Plan: Heavy Vehicles / Mobile Equipment’s movement Activity / Process Hazards associated Means to address Hazards Helperless Driving Heavy Vehicles / Mobile equipment's movement 27 Hit, dash, collision, run-over Measures Fool Fail Soft Proof Safe Use of reflective stickers to heavy vehicles Separate walk ways for pedestrian within each site Flag man to guide heavy mobile vehicles Access control thru physical barriers Mandatory use of high visibility jackets Rest rooms near workplace at site Side & Rear Run under protection guards to heavy vehicles Weekly monitoring of illumination level Heavy vehicle fitness checking thru weekly audits

Pedestrian Walkways within sites 28

Run-over Protection Guards & Flagman 29

Use of High visibility jackets & other PPEs 30

Heavy Vehicle & Mobile Equipment Safety Use of Reflective Stickers 31 Heavy Vehicle Audits

Action Plan: Electrical & Moving Machinery Hazards Activity / Process Hazards associated Measures Means to address Hazard Compliance to Temporary Electrical Wiring standard Fool Proof Electrocution, Implementation of Positive Isolation Electrical Injury due to Earthing of tools, appliances and equipments Electric Flash Goal Post below HT lines Fail Safe Fail Soft Moving Machinery & Stored Energy Fire extinguishers and rubber mat at Electrical DB rooms Guarding of chains and rotating parts Hit, crush, Maintaining safe distance between moving material and rigger entrapment Presence of Flag Man for earth moving equipments and heavy vehicles 32

Fool Proof : Goal Post below HT line crossing 33

Placement of Rubber Mat in front of Electrical Panels 34

Action Plan: Improve Road Safety Activity / Process Hazards associated Measures Means to address Hazards Fool Fail Safe Fail Soft Proof Road Safety Awareness Campaigns Audio-visual alarms & signage Deputing Road Traffic Volunteers / Flag Men Restricted movement of two wheelers inside Road Safety Crush, hit, site dash, One way traffic inside site collision, Access control system (Safety Induction Pass run-over System) Training on defencing driving to drivers Audits for intoxication checking for drivers Speed Monitoring camera inside site 35

Road Safety Initiatives Deployment of Flagman 36 Speed barriers at junction points

Road Safety Display of Road Safety Signage & Directional Board (One Way Traffic) 37

Action Plan: Safety during Excavation Activity / Process Hazards associated Means to address Hazard Hard barrication to excavated pits and use of net Excavation Measures Fool Proof Fail Safe Fail Soft Periodic Excavation Inspection Report for monitoring Slope Ratio, Shoring, Shielding, Barricades, Water Removal and Over burden at edge Fall from height, Monitoring stability of earth moving entrapment equipments Use of rebar caps for improved visibility & to protect sharp edge Verification of excavation safety standard thru Checklist 38

Hard barrication & benching at Excavated Pits 39

Use of Rebar Caps 40

Action Plan: Fire Management & Confined Space Activity / Process Hazards associated Measures Means to address Hazard Hot work checklist Fire Management Confined Space Heat / Burn Fire Fighting Training injury Audits for Fire Safety Fire Tenders and Extinguishers Compliance to Confined Space Standard Gassing, System of gas detection and impact Poisoning, assessment Asphyxiation 41 Work Permit for Confined Space Fool Proof Fail Safe Fail Soft

Fire Fighting Training & Demonstration 42

Spatter Protection while Hot Work at Height 43

Display of Emergency Contact Numbers and Communication 23/05/12 44 23/05/12

Employee Recognition 45

Safety Communication in Local Language 46

Safety Communication in Local Language 47

Let’s join hands to make SAFETY a way of Life…. !! 48

49

Thank You Journey Continues…. . ! 50

Back-up Slides 51

Process Safety Development Phases in Major Projects Project Phase Risk Review Phase Name Goals of Risk Review Methodology Choosing inherently safer option, - Consequence modelling 1&2 Conceptual ensure overall feasibility, estimate - What-If (no guidewords) impact on neighbours - Selected checklist for judging inherent safety Identify & resolve most expensive design alternatives, including layout of - What-if (no guidewords) Preliminary 3 plant, facility siting concerns, - HAZOP / FMEA of selected scenarios Design environmental protection issues and - Layers of Protection Analysis (LOPA) of selected scenarios major tie-ins Identification of potential accident - HAZOP / FMEA of equipment nodes, focusing on normal scenarios, preliminary focused on mode of operation Detailed 4 normal mode of operation - What-if of lower consequence & lower complexity systems Design Begin risk assessment for scenarios with LOPA of 1 -5% of the scenarios: Determine Safety Integrity large residual risk Level (SIL) Update results of previous Risk Review - Complete HAZOP, FMEA or what-if for nodes started in for new details, identify potential previous Risk Review accident scenarios for nodes not - Perform HAZOP, FMEA, What-if for nodes not covered in previously reviewed, primarily focused previous Risk Review (due to previous missing info) 5 Final Design on normal mode of operation. Resolve - Begin Human Factors and Facility Siting checklist most previous recommendations - Perform general Utility Failure checklist Complete risk assessment for scenarios - LOPA of 1 -5% of the scenarios: determine SIL, as necessary with large residual risk 52

Process Safety Development Phases in Major Projects Project Risk Review Phase Name 6 Commissioning 7 Post-Start-up Goals of Risk Review Methodology Conduct full hazard / risk review of operating procedures to - HAZOP (2 guideword or 8 guideword) or What-if (no control risk of errors during start guideword) of operating procedures (choose method -up, shutdown & other nonbased on hazard & complexity of each task) - Complete HAZOP, FMEA or What-if for nodes started in routine modes of operation Close out previous Risk Review previous risk reviews issues (from earlier phases of - Perform HAZOP, FMEA, What-if for nodes not covered in project) and complete human previous risk reviews (due to previously missing info) factors and facility siting - LOPA of 1 -5% of the scenarios; determine SIL, as checklist necessary This Risk Review creates "Initial - Complete Human Factor and Facility Siting checklist PHA" of the process Conducted after 3 -6 months - Audit of MOCs (and P&IDs and SOPS) since "Initial PHA" after start-up similar to the to ensure noting has been missed by MOC future Revalidation, but with the - HAZOP or What-if of missed or poorly reviewed changes goal of compensating for - Update PHA for the entire set of changes (looking at a weaknesses in MOC process at whole picture for the effect of all changes) the initial start-up of the new - Close any pending recommendations (if possible) unit / process 53

DO IT 1. Define critical behaviours to improve, 2. Observe target behaviours during a baseline phase to set specific goals for achievement, 3. Intervene to change the target behaviours in the desired direction, and 4. Test the impact of the intervention by continuing to observe the target behaviors. Consider the power of rewarding safety feedback to increase safe work practices. Praising people for safe work practices: 1. Increases the probability that these work practices will be performed safely in the future, 2. Builds a more open and positive safety culture 54

Managers Role to Improve Safety Culture 1. Safety rules are consistently and fairly enforced. 2. Suitable personal protective equipment (e. g. , safety glasses, harnesses) is readily available to employees. 3. Work schedules don’t compromise employees’ safety (e. g. , excessive overtime, unrealistic production pressure). 4. Management spends sufficient time on the floor interacting with employees. – This increases employee input for safety. – This shows employees that “management cares”. 5. Employees are actively involved in managing safety efforts. 6. Safety management systems (e. g. , training, discipline) are in place and effective. 55

Backup for Challenges in Construction slide Properties : Dynamic in Nature Frequent work team rotations, Exposure to changing weather conditions, High proportions of unskilled and temporary workers. The safety record of the construction industry is very bad w. r. t. other industries due to Complexity of the work or system, Risk nature of works, Management commitment and way of working, Safety knowledge and commitment at individual level Personal behaviour 56

Targets : Lead Indicators Proactive Safety Measure Tools Target Timelines Imparting Pre-employment & job specific training 100% Implemented & Ongoing Compliance to Work Permit System 100% Implemented & Ongoing Safety Communications: Mass Meeting Job specific hazards communication thru PEP talk - Monthly per site - Daily at the start of the shift Implemented & Ongoing Visual SOPs in local language Promoting culture for Near Miss incidence reporting Job Cycle Checks Safety Observation visits by TSL employees 2 per AIC As & When happens 1 per officer 3 per officer Contractor Safety Audits for identifying severity 4 & 5 observations and corrections by: - Contractor Supervisors - Daily - AIC / SIC - Twice a week - Safety Professionals - Thrice a week Incident Investigation Pre Start up Safety Review for all critical equipments As & When required Monthly On-going FY 14 57

Stamp Charged Coke Ovens 1. 5 mtpa 3. 0 mtpa Blast Furnace Sinter Plant 496 m 2 x 1 no : 5. 75 mtpa Pellet Plant : 5. 0 mtpa 4300 m 3 x 1 no: 3. 2 mtpa 4300 m 3 x 2 nos: 6. 4 mtpa Converter 310 t x 2 nos: 3. 1 mtpa 310 t x 3 nos : 6. 2 mtpa Lime Plant 600 tpd x 2 nos: 0. 4 mtpa 600 tpd x 3 nos: 0. 6 mtpa Unit Phase – 1 (Comm : 2013) Phase – 2 (Comm : 2015) Slab Caster 2 strand x 1 nos: 3. 00 mtpa 2 strand x 2 nos: 6. 00 mtpa Hot Strip Mill 2000 X 25 mm: 3. 5 mtpa 2000 x 25 mm : 5. 5 mtpa Cold Rolling Mill 1870 X 0. 3 mm: 2. 2 mtpa

Line Management Accountability & Responsibility: ‘The only proven way of achieving Excellence in Safety Management’ • Felt Leadership: Developing culture to accept Safety as personal responsibility for themselves and those reporting to them • Accountability of line managers for the Safety Performance in their area of responsibility • Safety information sharing during daily safety meetings, Mass meetings, AIC & SIC meetings • Visible in area of work through frequent safety site visits for observations (safety contacts) and Contractor Safety Audits 59

Construction & Contractor Safety Management • Providing training on Contractor Safety Audits to contractor’s Supervisors. Support and hand-holding by TSL Project Managers & Safety Professionals • Daily Audits by site supervisors of Contractors & Consultants, Weekly Site Audits by AIC / SIC members & twice a week audits by TSL safety professionals for identification and immediate correction of severity 4 & 5 observations • Managing Contractors’ Safety performance in accordance to the same safety standards and procedures as with our own employees • Clarity on Safety expectations wrt Tata Steel Standards & Procedures & procedures to all Contractor owners thru Contract Terms 60

Process Safety Risk Management • Formation of PSRM Safety Subcommittee team & Training on PSRM to bridge knowledge gap • Plant and Equipment from Technological Leaders having in-built safety features (Examples: HAZOP approvals for all designs prior to manufacturing & supply, Covers for all cast house runners, in-built lockable positive isolation features in all electrical panels) • Incorporation of specific Safety features in design of plant & equipment based on past learning (Examples: automatic drill bar changer for all tap holes in Blast Furnace cast house, enclosed type goggle valves for gas lines for elimination of gas exposure & positive isolation using hydraulic locking for cast house machines) • Ensuring adequacy checks of safety features at design stage using PSRM. Quantity Risk Analysis in High Hazard Operations viz. Gas holder, BF Bleeder etc. 61

Procedures & Performance Standards • Deployment of TSL Safety Standards with focus on phase-wise activities involved • Safe Work Procedures for all the jobs & activities • Safe Operating Procedures in local language for day specific work, hazards associated and mitigation measures • Job Cycle Checks by TSL employees to bridge gap in deployment of SWP • Shift-wise / Daily / Weekly / Monthly verification of compliance of ‘physical conditions’ of critical Standards (Excavation, Gas Cutting & welding sets, material handling Checks on • Task-based Risk Assessments for the high hazard / more critical tasks 62

Positive Isolation My Life is My Life: Positive Isolation Safety Subcommittee is working on following : a) Energy Source Identification (Establish and approve procedure for Isolation points, Method of isolation & The locking points) b) Accreditation / Authorization for Isolating Persons • • Formulation of Isolation Procedure for the Complex Isolation and Energy Source Identification document • Deployment of equipment isolation using Personal Locks & System Locks thru contractors is at early stages • Implementation of Methods of Isolation (i. e. Control Stop, Individual, Group & isolation for working alone) 63

Safety Observation & Audit Process Working on Safety Management System that includes two types of audits: • Behavioral Audits - to assess people and their conduct (Focuses on identifying, disclosing and eliminating deviations resulting from improper, inappropriate and/or unsafe behavior and conduct) • Managerial Audits - to assess the management system in terms of its appropriateness and compliance (Assess levels of efficiency of the Process Risk and safety management system) ● Effective use of 6 -Step Safety Observation technique with focus on behavior change thru Safety Contacts (identification of risks and mitigation measures) ● Rewards for Positive behavior & Consequence for repetitive negative behavior 64

Incident Investigation • Proactive implementation of learning from incidences at Jsr / other sites by parallel deployment of key relevant recommendations • Addressing root causes thru Engineering Solutions / safeguards in Design Stage • Reporting & timely investigation of all incidents (tendency to hide & difficulty due to skewed ratio of workmen to supervisors) • Promoting timely reporting of Near Misses by reward & recognition (for contract employees) ● Class room training on Incident Investigation for new recruits, project managers of contractors 65

Road & Rail Safety Road Safety - Major area of concern during Construction Phase Physical: • Uneven approach, narrow & loose soil (non-compact) roads • Major excavation work and land filling activities : Heavy movement of earth moving equipments • Outsourcing of dumpers by major contractors to multiple sub-contractors • Non-uniform illumination at construction sites • Incomplete periphery fencing / boundary wall • Pre-employment training facilities inside site Human: • Deployment of non-educated drivers and helpers • Overtime working by drivers • Intoxication habits of local people • Delay in implementation of Gate Pass System 66

Rail & Road Safety Actions taken and In-process / Proposed: • • • Heavy vehicle audits by CFT as per checklist Detailed mapping of roads for material movement Implementation of One way traffic & display of sign boards Deployment of Road Safety commandos on junctions Road Safety awareness Campaigns and posters Site-wise assigned parking place for heavy vehicles • • Focus on constructing roads at site on priority before monsoon Separate route for entry and exit of light & heavy vehicles Restricted / No entry for two & three wheelers inside plant Monitoring of driving habits through electronic technology Driving permits to be revoked before violations become collisions Defensive driver training for issuing permit to drive at site Proactive implementation of learning on Rail Safety from Jamshedpur 67

Occupational Health and Environment Actions taken and In-process / Proposed: • Provision of Rest rooms and drinking water at each site • Installation of First aid Boxes, 1 First Aid Centre and 3 First Aid outposts • Procurement of Critical Care Ambulance • Creating pool of trained and certified First Aiders • Recruitment of Doctors and paramedical staff in process • Maximize Solid Waste Utilization • Green Belt Development • Labour Colony – Health & Hygiene Issues • Recycling of bio-waste 68

Training & Communication • Leadership training with a focus on the behavioral aspects of safety for all external recruits • Pre-employment Safety training / induction by external agency (NTTF) to all categories of workers and re-training every six months ● Contractor Safety Audit training to Contractor’s Senior Management to Site Supervisor level and weekly monitoring of audit compliance ● Monthly Safety Newsletter in Local language to connect with family ● Plan to conduct: ● Theme based safety awareness training on monthly basis thru visual SOPs / Models, Do’s & Don’t in Safety Excellence Center (Infrastructure & facilities creation under progress) ● Contractor Orientation training for Sub-contractors 69

Consequence Management & Motivation: “Motivation”: The most important task and frequently the most difficult: • ‘Walk the Talk’ and demonstration of passion for Safety at all levels • Constant communication on ‘Importance of Safe behavior’ • Involving maximum possible employees in Safety initiatives • Timely addressing Safety concerns raised by employees • Acknowledging and appreciating safe act / behavior • Internal competition by recognizing Safe workplace • Consequence Management : Safety is the precondition of employment 70

Fool Proof / Fail Safe Approach Created by: OS 0059 Date: 8/13/2010 Doc. Classification: Public

Fool proof: Following or executing such a plan that will eliminate the root cause. So that even a fool will not be able to commit mistakes. This can be done by providing mechanization or automation Fail Safe: Planning in such a way that even if the situation arises, the effect will be zero for e. g. a person may fall from height in case he stumbles, but will be safe if he wears safety belt Fail Soft: Planning is done in such a way that even if situation arises, the effect can be minimized for e. g. A person may fall while driving two wheeler, but will be hurt less if he is wearing helmet

Commonly used fool proof 3 pin plug All Electrical/Electronics connectors. Commonly used Fail Safe