CHAPTER – 23

Safety in Construction Industry

THEME

1. Industries Needing Attention 20. Hazardous Chemical and Processes

2. Asbestos Manufacture and Handling 21. Flammable Liquids and Gases
3. Automobile Industry 22. Leather Industry
4. Benzene Manufacture, Handling and Use 23. Paper Industry
5. Beverage Industry 24. Pesticide Industry
6. Brick and tile Industry 25. Petrochemical Industry
7. Canning and Food Industry 26. Petroleum Refinery and LPG Bottling Plants
8. CS2 and H2S Plant 27. Pharmaceutical Industry
9. Carcinogenic Dye-Intermediates 28. Plastics Industry
10. Cement Industry 29. Polymer Plants
11. Chemical works 30. Pottery Industry
12. Clothing Industry 31. Rubber Industry
13. Dairy Products Industry 32. Ship Building, Repairing and Breaking
14. Electronics Industry 33. Silk Industry
15. Electroplating Industry 34. Soap Industry
16. Fertilizer Industry 35. Solvent Extraction Plant
17. Fireworks and Match Factories 36. Sugar Industry
18. Food Industry 37. Tobacco Industry
19. Glass Industry 38. Woodworking Industry

1. INDUSTRIES NEEDING ATTENTION

Three questions are important from safety point of view:

1. Which industries are more in number?

2. Which industries employ more men-power?
3. Which industries have more accidents?

According to the number of working factories (as per Table 5.16 in Chapter-5) the chronological
order is as follows:

1. Chemical and Chemical Products.

2. Non-metallic Mineral Products.
3. Machinery and Parts.
4. Wool, Silk and MMF.
5. Food Products.
6. Metal Products and Parts.
7. Basic Metal and Alloy Industry.
8. Cotton Textiles.
9. Rubber, Plastic and Petroleum.
10. Wood and Wood Products.
11. Paper and Paper Products.
12. Electrical Machinery and Parts.

Fundamentals of Industrial Safety and Health 23- 1 Safety in Construction Industry

13. Other Manufacturing.
14. Transport equipment parts.
15. Textile Products.
16. Repair services.
17. Beverages, Tobacco.
18. Repair of Capital Goods.
19. Education, Science & Research Services.

According to the number of workers employed, (as per Table 5.16 in Chapter-5) the chronological
order is as under :
1. Chemicals and Chemical Products.
2. Cotton textiles.
3. Wool, Silk and MMF.
4. Food Products.
5. Non-metallic Mineral Products.
6. Machinery and Parts.
7. Rubber, Plastic and Petroleum.
8. Basic Metal and Alloy industry.
9. Metal Products and Parts.
10. Electrical Machinery and Parts.
11. Paper and Paper Products.
12. Transport equipment & parts.
13. Other Manufacturing.
14. Repair services.
15. Textile Products.
16. Electricity, generation, transmission & distribution.
17. Wood and Wood Products.
18. Beverages, Tobacco.
19. Education, Science & Research Services.
20. Repair of Capital Goods.
21. Water Works & Supply.

According to the number of accidents, (Table 5.22 in Chapter-5) the order is :

1. Cotton textiles.
2. Machinery and Parts.
3. Chemicals and Chemical Products.
4. Wool, Silk and MMF.
5. Basic Metal and Alloy industry.
6. Non-metallic Mineral Products.
7. Rubber, Plastic and Petroleum.
8. Repair of Capital Goods.
9. Metal Products & Parts.
10. Repair Services.
11. Food Products.
12. Other Manufacturing Industries.
13. Paper and Paper Products.
14. Transport Equipment &: Parts.
15. Jute & other Vegetable Fibre Textile.
16. Wood and Wood Products.
17. Beverages, Tobacco.
18. Textile Products.

Fundamentals of Industrial Safety and Health 23- 2 Safety in Construction Industry

 An all India order (as per Table 5.9 in Chapter5, for the year 1990) according to the number of
injuries (frequency rate) is as follows :
1. Jute & Vegetable Fibre Textiles.
2. Cotton Textiles.
3. Non-conventional Energy Generation.
4. Other Manufacturing Industries.
5. Rubber, Plastic & Petroleum.
6. Gas & Steam Generation & Distribution.
7. Transport Equipment.
8. Basic Metal Industries.
9. Non-metallic Mineral Products.
10. Wool, Silk & MMF.
11. Electricity, generation, transmission & distribution.
12. Food Products.
13. Paper and Paper Products.
14. Repair of Capital Goods.
15. Chemicals & Chemical Products.
16. Wood and Wood Products.
17. Textile Products.
18. Metal Products & Parts.
19. Beverages, Tobacco.
20. Machinery.
21. Leather & Leather Products.
22. Water Works & Supply.

According to the number of accidents in Gujarat and India, textile industry has the highest number
of accidents and injuries. But this trend is changeble.

In Gujarat, numberwise and workerswise chemical industry is at the top.

Out of above industries, we have studied so far up to the last chapter, the cotton textiles,
chemicals, synthetic fibres, machinery, metal products, basic metals and alloy industries and electrical
machinery industries. Therefore the statutory provisions and the safety aspects with inspection
experience of the remaining main industries are given below in brief.

2 ASBESTOS MANUFACTURE AND HANDLING

Asbestos-chrysotile, crocidolite or amosite in natural fibrous silicate forms - is a white, blue or

grey brown substance (available from 1880). It is a cheaper man-made mineral fibre used for many
products. Its main uses are in asbestos-cement products as roofing sheets, pipes and wall boards.

Asbestos dust causes lung damage. Fibrosis of the lung by asbestos was first described with PM
report by Montague Murray in 1899. The name asbestosis was given by Cooke in 1927.

Control of airborne contamination becomes difficult and costly. Therefore effective enclosures to
source of generation and local exhaust ventilation on machine, wetting of fibres before mixing, spinning
and weaving, vacuum cleaning instead of brushes and changing of clothing at the end of work are the best
controls. Dust masks are also essential.

Fundamentals of Industrial Safety and Health 23- 3 Safety in Construction Industry

 Asbestos dust is a confirmed human carcinogen and its STEL/CEILJNG values published by
ACGIH are as under :

Crocidolite - 0.2 fibre/cc

Amosite - 0.5 fibre/cc
Chrysolite and other forms - 2.0 fibre/cc

The 2nd Sch. of the Factories Act gives this value as 2 fibres/ml (length 5 nm and breadth 3 )Lim
as respirable dust).

Asbestosis is an occupational disease specified in the 3rd Schedule of the Factories Act. See Part
4 of Chapter-24 for further details.

Statutory Provisions:

Summary of Schedule 17, rule 102, GFR i.e. Gujarat Factories Rules, Sch.17 u/r 114, MFR i.e.
Maharashtra Factories Rules and Sch.20 u/r 95 of the TNFR i.e. Tamil Nadu Factories Rules is as under :

Application :

This schedule is applicable to the process of asbestos in any form of making insulation slab or
mattresses, textile, cardboard, paper, cement goods consisting asbestos or spraying asbestos or cleaning
asbestos dust. Definitions:

Asbestos is a fibrous silicate mineral and any admixture of silica known by different names. Its
dust means airborne particles. Respirable asbestos fibres means those having diameter less than 3 m and
a length to diameter ratio greater than 3:1. Other terms are also defined.

Tools and Equipment:

They should not create asbestos dust above the permissible limit or they should be equipped with
efficient exhaust draught.

Prohibition :

Processes of tools releasing asbestos dust beyond the permissible limit, use of crocidolite,
spraying of asbestos and installation of friable asbestos insulation materials are prohibited.

Employment of young persons and smoking are also prohibited.

Substitution :

Asbestos shall be used only when its risk can be prevented or controlled, otherwise it shall be
replaced by other less harmful or harmless material or technology.

Restriction :

Number of persons exposed to asbestos and their exposure time shall be kept minimum. Their
work area shall be 'demarcated by warning signs restricting unauthorised access.

Exhaust draught:

Fundamentals of Industrial Safety and Health 23- 4 Safety in Construction Industry

 An efficient exhaust draught shall be provided and maintained to control dust from the process
and machines prescribed in para-4 (1) of the Schedule. Dust coming from the exhaust apparatus shall be
collected by filter bags or suitable receptacles and shall not be drawn free into the air of any work room.

Testing of Ventilation System :

A responsible person shall inspect the system every week. A competent person shall test it every
year. Defects found shall be rectified forthwith. Test report shall be in form No. 26-A.

Segregation :

Dust creating work places shall be segregated from other work places to avoid exposure to other
workers.

Breathing Apparatus & Protective Clothing :

An approved type of breathing apparatus and protective clothing shall be given to workers, for
working in chamber or cleaning dust or filling , beating or other operation where it is not possible to keep
the dust within permissible limit. Separate accommodation shall be provided to put on or take off such
apparatus and clothing and to store when not in use.

All protective clothing shall be deducted under an efficient exhaust draught or by vacuum
cleaning and shall be washed at suitable intervals. The cleaning schedule and procedure shall be
established to ensure the efficiency of protection.

They shall be cleaned and disinfected at suitable intervals and inspected every month by a
responsible person.

A record of cleaning and maintenance shall be maintained. Full instruction shall be given to the
user before employing in such work. No apparatus worn by a person shall be worn by another person
unless it has been thoroughly cleaned, disinfected and full instruction given to that person.

Separate accommodation other than that for breathing apparatus, shall be provided to store other
personal protective equipment or personal clothing.

Washing and Bathing Facilities :

Washing places shall be provided at the rate of I for 15 persons. Stand pipe separation shall be
more than a metre. Constant water, clean towels, soap, and nail brushes shall be provided. Washing
(bathing time of 30 minutes within working hours) shall be provided at the end of the shift.

Mess Room :

A suitable mess room with tables, benches (with back rest) and means to warm food shall be
placed under the charge of a responsible person and be kept clean.

Cautionary Notice :

Cautionary notices regarding (i) Health hazards from asbestos dust (ii) Need to use appropriate
equipment and (iii) Entry of authorised persons with protective equipment or no entry shall be displayed.

Fundamentals of Industrial Safety and Health 23- 5 Safety in Construction Industry

Labelling:

The container of asbestos or its products shall be labelled with warning of dust hazard and its
safety measures. MSDS shall be supplied to consumers.

Information regarding health hazards of home carrying contaminated clothing shall be given to
the families of the workers.

Air Monitoring :

Monitoring of asbestos fibre in air shall be carried out once in every shift. Time weighted average
concentration shall be calculated or measured by Membrane Filter Technique (MFT). Records shall be
preserved for thirty years.

Medical Tests and Records :

1. A doctor shall be employed with the approval of the CIF*. Medical facilities shall be provided to
him.
2. The CS** will examine a new worker within 15 days of his first employment. This will include
pulmonary function tests, tests to detect asbestos fibres in sputum and chest X-ravs. No worker
shall be employed without: Fitness Certificate in Form No. 27 A by the CS.
3. Periodical tests every year by the CS.
4. Health Register in Form No. 20 to be signed by the CS. Reasons of unfitness shall be recorded in
it. Re-employment in the same process is possible with a Fitness Certificate from the CS.
5. Post Medical Examination shall also be carried out. No cost to the workers. Results shall not be
used to discriminate against the worker. Workers will be informed about the test results. If health
is impaired due to long time exposure, the worker shall be compensated to maintain his income.
6. Records of Medical Examinations shall be preserved for 30 years. On closure of the factory, the
records shall be deposited to the Office of the GIF.

* CIF = Chief Inspector of Factories

** CS == Certifying Surgeon

Other Provisions :

1. Loose asbestos, while not in use, shall be kept in closed receptacles.

2. A sack containing asbestos shall not be cleaned by hand beating but by a safe machine.
3. Disposal of waste should not pose health hazard to workers or the public in the vicinity.
4. All floors, work benches, machinery and plant shall be kept clean and free from asbestos dust.
Vacuum cleaning equipment shall be used, otherwise respirators will be given to the cleaners.
The cleaning apparatus shall also be cleaned for asbestos waste and dust.

IS : Safety and health requirements relating to exposure to asbestos 11451, Asbestos dust control
11770, cleaning premises 11767, airborne concentration 11450, chrysotile 9690, 11276, 11267,
Manufacturing premises - exhaust ventilation system 12080, packaging, transport & storage 12079,
personal protection of workers 12078, products safe use 11769, terminology 11707, workplace pictorial
warning 12081, products 5913, control recommendation 12082, corrugated sheets 459, 13008, asbestos
fibre 2712, 11275, 9745, yarn 13362.

3 AUTOMOBILE INDUSTRY
Fundamentals of Industrial Safety and Health 23- 6 Safety in Construction Industry
 This is a part of an engineering industry and carries out various processes like casting, forging,
machining, electroplating, painting, assembly, testing etc. The safety measures include :

1. Noise and vibration control.

2. Dust, fumes and gas emission control by
3. High temperature control near furnaces by insulating material or heat reflective surfaces to heat
source.
4. Heat protective clothing, eye and face protection.
5. Mechanical lifting.
6. Guarding of drilling, reaming, grinding, milling machines, power presses, conveyor belt etc.
7. Machine tools with splash guards.
8. Barrier creams and oil-resistant aprons. .
9. Welding and soldering precautions.
10. Electroplating baths with special lip ventilation and anti foaming surface tension agents.
11. Solvent and spray controls with special booths in painting shop Paint dipping and electrostatic
or electrophoretic painting requiring worker outside are more safe.
12. Dryers with exhaust ventilation.
13. Controls for chemicals which are toxic, flammable and explosive.
14. Electrical safety.
15. Precautions against silicosis, solvent poisoning, lead poisoning, skin diseases. X-rays for
nondestructive testing etc.

See Table 15 of Chapter-32 for TLVs of Silica and other chemicles.

IS : Safety Code for industrial trucks 6305 (Part I & 2), life jackets 6685, protective helmets 4151,
stability testing of forklift trucks 4357, 5752, 5753, conveyor safety 7155 (Part I to 7), glossary of terms
7862, smoke emission for diesel vehicles 8118, CO emission limits 9057, braking system 11852 (Part I to
7), driver safety 11939, life saving equipment 10548, speed limiters 10144, automobile accessories 8925,
8098, control cables 5836, electric equipment 9175, light-reversing 9961, stop, tail & turn signal lights
10256, wiring cable terminations 8395, Automotive vehicles - accelerator control, safety requirements
14283, air brake system 11852, 12831, 12821, electronic flashers 13135, pneumatic tyres 10914, rear
view mirrors 14210, registration plate 14224, side doors safety requirements 12009, terms & definitions
13111, windows for buses, safety requirement 13944.

4 BENZENE MANUFACTURE, HANDLING AND USE

Manufacture :

Benzene is a solvent frequently used in many organic processes. It is also used as a fuel, additive
of motor fuel, chemical reagent and a raw material for large number of chemical synthesis.

Old process of obtaining benzene is from coal. Its line diagram is as under :

Coal (1 ton)  Coke (1500 lb) + Light oil (3 gallons] + Coal tar (8 gallons) + Ammonium sulphate
(20 1b) + Illuminating gas (11200 cuft)

Fundamentals of Industrial Safety and Health 23- 7 Safety in Construction Industry

 Benzene and related compounds (toluene, xylene) are also obtained commercially by subjecting
open-chain alkanes obtained from petroleum to cyclization followed by dehydrogenation. This
conversation is brought about at high temperatures and pressures in the presence of suitable catalysts :

n-Hexane  catalyst  Benzene

n-Heptane  catalyst  Toluene

Benzene can also be produced by cyclization and aromatisation of paraffin hydrocarbons.

Benzene is the simplest member of the aromatic group of compounds. It is represented by a closed ring of
six carbon atoms as –

Hazards and Control:

Benzene is lighter than water (sp'. gr. 0.88) and heavier than air (vd 2.8). Its other properties are
BP 80.1 °C, FP -II °C, explosive range 1.3-7.1 %. It is less soluble in water, but highly soluble in organic
solvents and oils.

Looking to its very hazardous nature, the ILO passed its Benzene Convention 1971 (No. 136) and
Recommendation 1971 (No. 144).

It is highly flammable, explosive and toxic, all at a time. It exerts acute as well as chronic
poisoning. Its TLV is 10 ppm (30 mg/m3), STEL 25 ppm (75 mg/m3) and IDLH 2000 ppm. ACGIH
booklet 2007 shows TLV (TWA) as 0.5 ppm and STEL as 2.5 ppm.

Fatal cases of blood disease - leukaemia - have been reported. It destructs bone marrow. Benzene
handling must be in a closed system. Its exposure must be measured in work areas and the affected
person (by medical examination) must be immediately removed from exposure. Less hazardous
substitutes like toluene, xylene, cyclohexane and other suitable solvents e.g. alcohol, ketones, esters etc.
should be used. Good ventilation including exhaust ventilation, plant enclosures, flameproof fittings, leak
detector with alarm, environmental and biological monitoring (estimation of urinary phenols), breath
sampling, dyke surrounding storage tanks, curbs round the process vessels, elimination of sparks, flames
and excessive heat and effective fire fighting arrangement are necessary.

Statutory Provisions:

Schedule-20 u/r 102, GFR, and also as Schedule20 u/r 114 of the Maharashtra Factories Rules,
1963, (MFR) and as Schedule-27 u/r 95 of the Tamil Nadu Factories Rules, 1950 (TNFR) gives safety
provisions regarding manufacture and use of Benzene or substances containing benzene.

Fundamentals of Industrial Safety and Health 23- 8 Safety in Construction Industry

 This Schedule is applicable to manufacture, use, storage, packing or handling of Benzene or
substances containing benzene (means wherein benzene content exceeds 1% by volume).

Manner of using Benzene or its substitute (less harmful) includes enclosed system or equally safe
system.

Protection against inhalation prescribes enclosed system or efficient exhaust draft to remove
benzene vapours from the workroom so that its concentration in air does not exceed 25 ppm or 80 mg/ 3
Its measurement and report of concentration exceeding above limit to the Inspector are compulsory. The
workers exposed to such higher exposure shall be given necessary respirators.

To avoid skin contact suitable gloves, aprons, boots and vapour tight chemical goggles (not
affected by benzene) should be given to workers.

Other provisions include prohibition of employment of women and young persons, labelling of
name, danger symbol, toxicity and flammability, no misuse of benzene for hand cleaning etc., no food,
drink, smoking or chewing in the workroom, instruction regarding risks, cautionary notice (as per
Appendix-B), washing facilities, cloak room and mess room, medical examination, pre-employment and
six monthly medical examination including blood test and other biological tests and temporary shifting of
the exposed worker.

Appendix-A specifies the processes where benzene substitute is not possible i.e. its production,
chemical synthesis and motor spirit (use of fuel).

Appendix-B is a cautionary notice specifying the hazards, preventive measures, protective

equipment and first aid measures in case of acute poisoning. It is reproduced below :

APPENDIX B

(A) The hazards :

1. Benzene and substances containing benzene are harmful.

2. Prolonged or repeated breathing of benzene vapours may result in acute or chronic
poisoning.
3. Benzene can also be absorbed through skin which may cause skin and other diseases.

(B) The preventive measures to be taken :

1. Avoid breathing of benzene vapours.

2. Avoid prolonged or repeated contact of benzene with the skin.
3. Remove benzene soaked or wet clothing promptly.
4. If any time you are exposed to high concentration of benzene vapours and exhibit the sign
and symptoms such as dizziness, difficulty in breathing, excessive excitation and losing of
consciousness, immediately inform your - Factory Manager.
5. Keep all the containers of benzene closed.
6. Handle, use and process benzene and substances containing benzene carefully in order
to prevent their spillage on floor.
7. Maintain good house-keeping.

(C) The protective equipment to be used :

Fundamentals of Industrial Safety and Health 23- 9 Safety in Construction Industry

 1. Use respiratory protective equipment in places where benzene vapours are present in high
concentration.
2. In emergency use self-generating oxygen mask or oxygen or air cylinder masks.
3. Wear hand gloves, aprons, goggles and gum-boots to avoid contact of benzene with your
skin and body parts.

(D) The first aid measures to be taken in case of acute benzene poisoning:

1. Remove the clothing immediately if it is wetted with benzene.

2. If liquid benzene enters eyes, flush thoroughly for at least 15 minutes, with clean
running water and immediately secure medical attention.
3. In case of unusual exposure to benzene vapour call a physician immediately. Until he
arrives, do the following :

If the exposed person is conscious -

1. Move him to fresh air in open.

2. Lay down without a pillow and keep him quiet and warm.

If the exposed person is unconscious -

1. Lay him down preferably on the left side with the head low.
2. Remove any false teeth, chewing gum, tobacco or other foreign objects which may be in
his mouth.
3. Provide him artificial respiration in case difficulty is being experienced in breathing.
4. In case of shallow breathing or cyanosis (bluish skin, lips, ear, finger, nail, beds), he
should be provided with medical oxygen or oxygen carbon dioxide mixture. If needed he
should be given artificial respiration.

IS : Benzene 534, safety code 4644, reagent grade 1840, insoluble matter determination 1214.

5 BEVERAGE INDUSTRY

Use of soft drinks (non-alcoholic carbonated and non carbonated or still drinks) is increasing day
by day. Industrial safety measures include :
1. Guarding of high speed bottling and canning machines.
2. Net or wire mesh screening under over head conveyors.
3. Nip guards on conveyor belts, drums and pulleys and frequent stop buttons for conveyors.
4. Ammonia respirators and water type fire extinguishers or sprinklers.
5. Bottling machines with strong shields to contain bursting bottles or siphons.
6. PPE to workers for protection against broken glass.
7. Containers for broken glass equipped with a hinged clover or long chute to prevent "fly back".
8. Mechanical handling.
9. Dry floors by proper draining and cleaning. Workers with safety shoes with tread type soles.
Tennis shoes and sandals not permitted. Waterproof aprons.
10. Fixed platforms (instead of portable ladders), catwalks and stair ways with open grating to mixing
tanks and elevated locations.
11. PPE and water showers for caustic splashes.
12. Waterproof and properly earthed electric fittings.

Fundamentals of Industrial Safety and Health 23- 10 Safety in Construction Industry

13. Noise control by reducing the number of impacts, speed of bottle travel, acoustic barriers,
enclosures and ear protection.
14. First-aid including waterproof plasters and dressings.

See also schedule I, Rule 102, GFR and also Sch.l u/r 114, MFR and Sch.l u/r 95 TNFR.

IS : Beverages (Aerated water)- protein based 7482, protein food 9038, carbonated 2346,
nonalcoholic 13019, sensory evaluation 8140, 8639.

6 BRICK AND TILE INDUSTRY

Bricks and tiles are essential building materials. Their clay work should include :

1. Chute feeds as protection against falls.

2. Guarding of presses, dies, tools, pug-mill gears and drives, rollers, edge runner pans.
3. Oiling, greasing and repairs only when the machinery is at rest.
4. Good lighting, flooring and electric fittings.
5. Dust producing equipment viz., crushers, vibrators, conveyor belts with' local exhaust ventilation.
6. Moistening of raw materials and premises to suppress flying dust.
7. If sand is applied, it should be made wet by mechanical means and local exhaust ventilation with
compressed air.
8. Glazes should be non-lead type. Lead is hazardous.
9. Correct draft conditions in kilns to prevent carbon monoxide.
10. PPE and clock room.
11. Mechanical handling.

Refractories (Substances with high melting point and good physical resistance) are of four types:
alumina-silicate, silica (or acid), basic and miscellaneous. Hazard control is as stated above. Here
chances of silicosis are more. Permissible concentration of fibrogenic dust should not be exceeded.
Manual breaking should be avoided. Mechanical crusher/ grinder with exhaust draft and dust collectors
or water or steam spray are essential. Floors should be cleaned by vacuum cleaning.

See Sch. 5 for grinding or glazing of metals and Sch. 18 for stone or other material containing free
silica, under Rule 102, GFR.

IS : Brickwork - measurement 1200, code of practice 2212, Brick-acid resistant 4860, alumina
8953, 14313, building heavy duty 2180, work with compressed air 4138, piling and deep foundations
5121, handling of building materials 7969, Falling hazards 13416 (Part I & 2), scaffolds and ladders 3696
(Part I & 2), Tiles cement concrete 10646, brick flooring laying 5766, insulating 2042, kiln, design and
construction 4805, paving 3583, sand lime 4139, silica mortar 1292, brick panel 14143.

7 CANNING AND FOOD INDUSTRY

There are six methods of food preservation heating, radiation sterilisation, antibiotic sterilisation,
chemical action, dehydration and refrigeration (frozen food industry). Industrial safety measures include :

1. Training for safe lifting, stacking and maintenance of good housekeeping. Mechanical
handling avoid manual hazards.
2. Machines designed for less spillage.
3. Floors clean, dry and drained.

Fundamentals of Industrial Safety and Health 23- 11 Safety in Construction Industry

 4. Protection against burns due to hot liquors,
5. Guarding of filling and closing machines, conveyor belts and drums, pulleys and gears.
6. Safety valves and pressure controls where steam is used.
7. Vaccination against infectious diseases, good personal hygiene, sanitary and washing
facilities.
8. For noise control sound absorbent mounting, magnetic elevators, nylon coated cables and
speed matching in can conveyor systems, use of plastic containers and ear protection.
9. Ventilation systems with special attention to condensation problems.
10. At ionising radiation, full protection, hazard monitoring, health screening and medical
examinations are necessary.
11. Control of lead levels due to side seam soldering. Avoidance of lead content.

IS : Canning fruit and vegetable hygienic code 6542, Food analysis handbook SP-18, bacterial
detection 5887, 7688, sampling and tests 1699, freezers, safety 10542, processing units 2491, 8077,
cereals, warning 1656, 1657, safe use of packing 7277, 7288, 7961, food colours 5346, test for dye
content 6120, food mixers, electric 4250, food container, metal 6093, hawker, hygienic conditions 10973,
plastic for packaging 10171, food poisoning bacteria 7688, food samples analysis 5404, food yeast 3839,
food service establishments 6074, 7021, 8220.

See Part 18 also.

8 CS2 and H2S PLANT

Carbon di or bisulphide, CS2 is found in coal tar and crude petroleum. It is produced by heating
charcoal with vaporised sulphur or by reacting sulphur with petroleum hydrocarbons. Reaction is C + S 2
= CS2 Pure product is obtained by distillation of crude CS2 and it is kept submerged in water.

It is a colourless, odourless gas with following .properties:

Sp. gr. 1.26 ER 1.3-50%

VD 2.6 IT 100 0C
BP 46.3 0C TLV,NIOSH 1 ppm
FP -30 0C TLV (skin) 10 ppm
30 mg / m3

IDLH 500 ppm (under the Factories Act & ACGIH)

Acute and chronic poisoning occurs in viscose rayon industry. CS, poisoning is a notifiable
disease in the 3rd Schedule of the Factories Act. It has toxic and fire hazard. It is a neurotoxin. Therefore
effect on CNS is the main symptom. It affects liver and kidneys also. Chronic poisoning begins with
headaches, fatigue, weakness and sleep disorder.

Safety measures require total enclosed system, general and local ventilation, exposure
measurement, iodine-azide test of urine (biological measurement), pre and periodic medical
examinations.

Statutory Provisions:

Fundamentals of Industrial Safety and Health 23- 12 Safety in Construction Industry

 Summary of Sch. 14 u/r 102, GFR, Sch.l4 u/r 114 MFR and Sch. 30 u/r 95 TNFR for CS 2 and H2S
is as under :

Amongst other definitions, 'efficient exhaust draught' is defined as localised ventilation effected
by mechanical means for the removal of gas or vapour, so as to prevent it, as far as practicable from
escaping into air of any occupied room. No draught shall be deemed to be efficient if it fails to remove
smoke generated at the point where such gas or vapour originates.

Other provisions include

1 Prohibition of employment of women & young persons.
2 Efficient exhaust draught on CS2 churn to keep CS2 exposure below 20 ppm, and also on H 2S
fumes. SBA necessary if ventilation is ineffective or stops suddenly, otherwise the worker shall
leave the room as soon as possible or within 15 minutes of such occurrence. Fresh air inlets shall
also be provided.
3 Air analysis to measure CS2 and H2S every 8 hours and its record. Exposure of CS 2 or H2S above
20 ppm, its duration and reason shall be reported to the CIF. Manager's duty to reduce the excess
exposure.
4 Electric fittings in CS2 fume process room shall be flameproof.
5 Washing facilities - 1 tap per 5 workers, standpipe within 1.2 mt spacing and sufficient supply of
soap and clean towels. 6 PPE as specified in the Table. Its use compulsory. Suitable storage
room or lockers necessary.
7 Mess room of at least 1 mt2 per worker, in charge of a responsible person and furnished with
tables, chairs, wash-basin and means to warm food.
8 Prohibition of smoking and source of ignition. Notice necessary.
9 Medical examination of workers employed in a fume process, by the CS (Certifying Surgeon)
every year. Record in Health Register.
10 Medical practitioner (MBBS with PG Diploma in Industrial Health or 5 years experience) and his
duties.
11 Breathing apparatus & life belts.
12 Cautionary placard and instructions.

Looking' to the prescribed TLV 10 ppm for both CS 2 and H2S, under the Second Schedule of the
Factories Act, that limit of 20 ppm stated in the State Rules should be changed to 10 ppm on safer side
and to bring uniformity in the provisions of the Act and Rules.

Summary of Schedule 22, rule 102, GFR, Sch.l9 u/r 114, MFR and Sch.26 u/r 95, TNFR is as
under

(1) Application:

This schedule is applicable to CS„, manufacturing plant containing electric furnace, condenser,
refiner and storage.

(2) Construction and operation :

Building should have optimum ventilation. Workers at risk of fire/explosion should be minimum.
Furnace should be sound with supports grounded 60 cms in concrete. Operating instructions to be strictly
followed.

(3) Electrodes:

Fundamentals of Industrial Safety and Health 23- 13 Safety in Construction Industry

 Seamless tubes with cooling water system giving alarm of interruption of water in the electrodes
and stopping power supply for furnace operation. Electrodes should be kept covered with charcoal bed.
Charcoal separator required between the furnace and sulphur separator to prevent charcoal entry into
condensers and piping.

(4) Rupture Disc and Safety Seal :

Two rupture discs on each furnace to blow off at. twice the maximum operating pressure. Water
sealing arrangement between charcoal separator and sulphur separator.

(5) Pyrometers and Manometers :

Pyrometers on furnace with dials in control room to know temperature of the furnace and
manometers to know pressure (1) before and after the sulphur separator and (ii) in primary and secondary
condensers.

(6) Check valves:

They are required on CS carrying piping to prevent back flow of gas in to the furnace in the event
of its shut down.

(7) Bulk Sulphur Storage :'

Sulphur dust being explosive, its clouds generation should be minimised and its contact with
spark, flame etc. should be prevented. Use non-sparking tools. Smoking, matches and sources of
ignition not allowed.

(8) Other provisions:

1. Inspection and maintenance by a competent person and in a prescribed manner.

2. Hourly record and log book for gas and water temperature, pressure, primary and secondary
voltages and current and energy consumed.
3. Fire/explosion proof electric apparatus, wiring and fittings.
4. Adequate means of escape.
5. Fire warning by electric and non-electric alarm.
6. Adequate number of fire extinguishers.
7. Trained workers and supervisors.
8. Washing facilities with one tap per five workers, pipe spacing more than 120 cms and soap, towel
etc.
9. Suitable PPE to workers.
10. Cloakrooms to put work clothing and personal clothing. In-charge person should be appointed.
11. Unauthorised, persons shall not be admitted in the plant.

IS : Code of safety for Carbon disulphide 5685, technical 717.

9 CARCINOGENIC DYE-INTER MEDIATES

Dye or dyestuff are soluble colours and the textile fibre or other materials are immersed in their
solution for dyeing process. Pigments are insoluble and are applied externally on surfaces by dispersion
methods.

Fundamentals of Industrial Safety and Health 23- 14 Safety in Construction Industry

 Finished dyes are not much hazardous but in making them many intermediates are manufactured
from hazardous chemicals like aniline, benzene, naphthalene, anthracene, acids and alkalis etc. and a
wide range of dye-intermediates are manufactured (e.g. quinones, aromatic amines etc.) and these
intermediates are hazardous and some of them are carcinogenic also.

Auramine and magenta have caused bladder cancer to the workers. Azo dyes derived from
benzidine or other chemicals, benzyl violet 4B, 4 amino or nitro diphenyland beta-naphthylamine have
carcinogenic potential.

Dermatitis is possible due to skin contact. Respiratory disorders have also been reported.

Statutory Provisions:

Summary of Schedule II, Rule 102, GFR, Sch.22 u/r 114, MFR and Sch.22 u/r 95, TNFR is given
below.

Applicability:

This schedule applies to factories where following substances are formed, manufactured, handled
or used –

Prohibited substances Controlled substances

Beta – naphthylamine and its salts Alpha naphthylamine or Alpha – naphthylamine
containing less than 1% of beta-naphthylamine.
Benazidine and its salts Ortho-toludine and its salts.
4 amino diphenyl and its salts Dianisidine and its salts
4 nitro diphenyl and its salts Dichloro Benzidien and its salts
Any substance containing above compounds Auramine and Magenta

No person shall be employed in process of 'prohibited substances' mentioned above except as

exempted by the CIF in writing. This becomes possible if the process is carried out in a totally enclosed,
safe and hermetically sealed system as prescribed in para23 of the schedule. The CIF may impose
conditions, if any.

Precautions for processes of 'Controlled substances':

1. Prevention of inhalation, ingestion or absorption of such substances.
2. Process in a totally enclosed system or under local exhaust ventilation.
3. Containers shall be tightly closed and properly labelled.

Other precautions:

1. PPE : Long trousers and shirts or overalls with full sleeves and head coverings, rubber gum boots,
rubber hand gloves, rubber aprons and respirator if required.

2. Prohibition: No women or young person shall be employed in such process. No person below the
age of 40 shall be employed in such process.

3. Floor: Smooth, impervious, no use of tar or asphalt, suitable slope, gutters and daily washing.

4. Empty containers: shall be thoroughly cleaned and inactivated before disposal.

Fundamentals of Industrial Safety and Health 23- 15 Safety in Construction Industry

5. No manual handling: Scoop with a handle shall be used. It shall be thoroughly cleaned daily. 6.
Instruction & Notice: All workers shall be instructed on properties of toxic chemicals and
their safe use including emergency procedure. Prescribed cautionary placards shall be displayed at
prominent places.

7. Washing/ Bathing facilities:

1. Wash places (basin) with clean towel, soap and nail brush to each worker, nearer to work
place.
2. Bathrooms with facility of hot and cold water.
3. One stand pipe on each floor.
4. Daily facility to wash uniforms.

8. Food, Drinks etc. - Food, drinks, pan-supari, tobacco and smoking in. workroom are prohibited.

9. Clock room: Lockers with separate compartments for street clothes and work clothes.
Separate place from locker room and mess room to store PPE given to the workers:

10. Mess room - With tables, benches and means to warm food.

11. Washing time - 30 minutes for bathing before the end of each shift and 10 minutes for washing
before each meal.

12. Medical Examination and Record

1. Employment of a doctor with approval of the GIF.
2. Provision of all medical facilities to him.
3. Examination by the CS within 15 days of first employment. It includes
haematological test, paranitrophenol in urine test, pulmonary function test and CNS test.
Employment after such fitness certificate (by the CS) only.
4. 6 monthly re-examination by the CS.
5. Fitness certificate in Form No. 33 and record in Health Register in Form No. 20. Ready to
be shown to the Inspector.
6. Unfit worker shall be given alternate placement. He can be re-employed in the same
process if declared fit by the CS.

IS : Carcinogenic substances, handling safety 14165, Dye application classes 4472, intermediates
sampling & tests 5299, pigment for paints 59, dyesbasic strength 12387, dye-hair, liquid 8481, disperse
dyes 11635, vat dyes 4394, 5970.

10 CEMENT INDUSTRY

Manufacture :

Cement is mainly made from limestone, clay and small amounts of other metallic oxides, which,
when mixed with a small amount of water, sets to a hard stone-like substance in a few hours. It is a main
building material working as a hydraulic bonding agent.

Types of cement are portland, pozzolana, calcium aluminate and special or corrosion-resistant
cement. Grades are more than fifty.

Fundamentals of Industrial Safety and Health 23- 16 Safety in Construction Industry

 Cement is a mixture of four essential raw materials i.e. 'calcium, silicon, aluminium andiron.
Calcium is obtained from limestone or cement rock or hydraulic calcium silicate i.e. clinker or chalk.
Silicon, aluminium and iron can be obtained together from clay or shale or slate or separately from sand,
bauxite on and iron ore respectively. Gypsum, fly ash and bias furnace slag are also added in certain
proportions Composition of these materials should be proper otherwise the property or quality may
change.

Manufacturing process is wet process (old one) dry process (new) or the combined process. The
raw materials are finely ground, mixed and heated (burned) in a rotary kiln to form cement clinker
During calcining, clinker compounds are also obtained. Various reactions such as evaporation of water,
evolution of CO and reaction between lime and clay take place during burning. Liquid formation begins
at 1250 °C and fusion occurs near the end of the process. Closed circuit grinding is preferred to open
circuit grinding. Process flow chart of the combined process is shown below.

I Storage-wetting (wet process)

Hazards and Controls :

In quarries where limestone, clay, gypsum etc. are extracted, hazards of dusts during drilling and
crushing, fall of rock and earth, blasting and bad weather conditions are obvious.

In cement processing area dust levels were found from 41 to 384 mg/m", the highest being at
sieving, cement packing and clinker grinding. Modern plants using wet process have 15-20 mg/nr" level.
Free silica content in dust is also possible. Electrostatic filters are useful to reduce the air pollution.

Fundamentals of Industrial Safety and Health 23- 17 Safety in Construction Industry

 High temperature near furnace doors, high noise (upto 120 dB) near ball mills, CO near limestone
kiln and dusting at most of the places including conveyor and manual handling cause health hazards.
Pathological disorders are found in respiratory, digestive and nervous system, and also in skin, hearing,
vision and rheumatic disorders.

Cement Pneumoconiosis may appear after prolonged exposure. Silicosis may not occur in cement
plant (because of. absence of free silica) but may occur in refractory processes due to dust containing free
silica.

TLV (ACGIH) for Calcium oxide is 2 mg/ m 3 and Aluminium oxide 10 mg/ " USSR-MAC values
are as under-:

Cement dust without free silica 6 mg/ m3

Cement dust with free silica <10% 5 mg/ m3
Asbestos cement dust with 5 mg/m3
asbestos >10%

2nd Schedule of the Factories Act prescribes 10 mg/nr" total dust containing less than 1% quartz as
permissible TWA concentration/8 hours TLV for Portland cement.

Similarly, the same Schedule prescribes 2 mg/ m 3 respirable dust fraction containing less than 5%
quartz as TLV for coal dust.

Cabins of excavators in quarries should be fully closed and the drivers should be supplied fresh
air through respirators. Modern surface mining machines do many operations safely. They dig the
surface, collect extracted material in ,a trailer, resurface the dug land and utilise wet process and dust
suppression system. Dust suppression measures near drilling, crushing and blasting, keeping away (at a
distance) from CO possibility at blasting points (fumes), enclosures to dusty processes and to conveyor
belts including their drives and transfer points, electrostatic and bag filters at clinker kiln stacks, sieving
and packing processes, cold air flow (showers) at hot places, thermal screening, shower baths and barrier
creams for skin protection and desensitisation treatment in case of eczema are all important safety
measures.

IS : Cement, hydraulic - glossary 4845, sampling 3535, physical tests 4031, flow table 5512,
chemical analysis 4032, colorimetric analysis 12423, bag, jute cloth 12001, jute bag for packing 2580,
polypropylene 11653, high alumina for structural use 6452, masonary 3466, mastic 3709, test for
permeability 3085, oil-well 8229, paint 5410, pipeasbestos 9633, 9627, plants-emission limits for
particulate matter 10693, control of air pollution 12002, plaster finishes 1661, Portland - blast furnace
Slag 455, high strength 8112, hydrophobic 8043, low heat 269, 12600, pozzolana 1489, rapid hardening
8041, sulphate resisting 12330, white 8042, rotary kilns 8125, refractories for kilns 10607, standard sand
for testing 650, Testing apparatus -10078, 5516, 5514, 5536, 7509, 7510, 9350, 5724, 5513,
waterproofing compounds 2645, Coal for manufacture 12770, cement concrete 12727, tiles for canal
lining .10646, asbestos cement-2098, 1626, 3140, 7639, 11450, bone cement 8681.

11 CHEMICAL WORKS

See Chapter-18 for safety in chemical industry.

Fundamentals of Industrial Safety and Health 23- 18 Safety in Construction Industry

Statutory Provisions:

Summary of Sch. 12 and 19 u/r 102, GFR is given below.

Sch.l2, Rule 102, GFR, Sch.l2,Rule 114, MFR & Sch.21, Rule 95, TNFR :

Sch.l2 is applicable to manipulation of sulphuric, nitric, hydrochloric and hydrofluoric acids or

liquid ammonia and hydroxide of sodium or potassium or mixture thereof.

Safety measures include acid and fireproof flooring, suitable PPE, safety showers, cautionary
notice, containers, crates and rubber-wheeled truck/ trolley to carry the containers safely, suitable tilling
or lifting device for emptying jars and carboys, scoop to handle alkalis, use of wooden implements to
clean acid tanks for prevention of arsine or H, production, storage of turpentine, carbides, metallic
powders and combustible materials not with acids and suitable fire extinguishers. 15 minutes washing is
suggested in case of acid or alkali burns.

Sch.l9, Rule 102, GFR and Sch.l6, Rule 95, TNFR:

Part-I Applicability and Definitions:

It is applied to all manufactures and incidental processes carried on in industries listed in the First
Schedule of the Factories Act.

The terms defined here include toxic substances, emergency, dangerous chemical reaction,
manipulation and confined space.

For other definitions see Chapter-2 and Part 2.1 of Chapter-16.

Part-II General Requirements:

Main points are highlighted as under:

1. House keeping :
Spillage to be cleaned. Floors, ways etc. free of obstruction. Easy means of access. Improper use
prohibited. No food, drink etc. in the work area. Cautionary notices and instructions regarding
fire, explosion, health hazard,' unsafe practices, symbols and colours used on labels. Undertaking

Fundamentals of Industrial Safety and Health 23- 19 Safety in Construction Industry

 from the workers within one month that they have read the notices and instructions, understood
them and would abide by them.

2. Preparation of new process :

All hazards of materials and reactions to be studied before staring any process or experimental
work. Details of hazards and measures from design stage to disposal stage shall be sent to the CIF
before 15 days of commencement.

3. Authorised entry :
Only authorised persons shall be allowed to work at dangerous chemical reactions or storage.

4. Test of Instruments and Safety devices :

Test before use. Monthly tests by a competent person. To be operated daily to ensure effective
working at all times.

5. Electrical installations :
Of appropriate type and conforming to IS.

6. Handling and Storage :

Containers of adequate strength, labelling, colour - coding, identification of hazard and safe
handling method. Use of damaged containers under supervision. Storage or charging should be
safe to avoid risk of fire, explosion and toxic concentrations above limits prescribed in the Second
Schedule of the Act. Suitable venting to maintain safe levels in vessels and containers. Type and
capacity of flooring and compatibility of substances shall be considered. Storage of highly
unstable, reactive or explosive material to be limited to the use of 2 months. For excess,
permission of the CIF is necessary. The CIF can direct to lower the limit of 2 months if more
safety is required. Standby arrangements for emergency transfer should be equal to the biggest
container. Non metallic vessels should be strong and independently supported.

7. Isolation:
Quick isolation facility with indication required.

8. Personal Protective Equipment:

They should conform to IS, should be in clean, sterile and hygienic condition before issue.
Information to workers for their use. For any doubts regarding appropriateness, the decision of the
GIF shall be final.

9. Alarms :
Audible and visible alarms in control room as well as at strategic locations for process correction
to control the parameters. They should be checked daily and tested every month. The CIF has
power to direct.

10. Control of Escape of Materials :

Enclosure, by-pass, exhaust, vacuum etc. required to control the escape and spread of hazardous
chemicals. In case of failure of such system, immediate steps necessary to stop further escape and
bring down to safe level. The escaped materials shall be diluted with water, air or suitable agent or
treatment.

11. Devices for Dangerous Reactions :

Automatic and/or remote control arrangements. In case of their failure automatic flooding,
blanketing or effective arrangements should come into operation.

Fundamentals of Industrial Safety and Health 23- 20 Safety in Construction Industry

12. Testing and Repair of Plant & Equipment :
Test by a competent person before first use. Then periodic test at 2 years interval, or after repair.
Detailed precautions are prescribed in para-15 of the Schedule in respect of pressure or reaction
vessels.

13. Staging:
Structure erected for maintenance, repair or for entering into confined space should be safe and
with access with hand rails. Toe board to work at a height of 1 mt or more.

14. Seating arrangements:

Should be safe to prevent risk of exposure to toxic, flammable & explosive substances.

15. Entry or work in Confined space :

Identify hazards and safeguards. Follow work permit system. Before testing wash, clean,
neutralise or purge the space and provide forced ventilation. Test for safe entering. Education,;
training and use of PPE for rescue, resurrection and first aid. Work under supervision. A log book
of such work should be maintained and shown to the Inspector on demand.

Fundamentals of Industrial Safety and Health 23- 21 Safety in Construction Industry

16. Maintenance work etc.:
All such work including cleaning of empty containers of hazardous chemicals, shall be done
under safety work permit system and by the trained workers under supervision. Place of such
work shall be cordoned off for safety of others.

17. Permit to work system :

It should be under supervision of knowledgeable and responsible person. Clean the work place by
washing, purging etc. Then isolate it from other parts throughout the period of work. Develop
predetermined work procedure for safety. Physical fitness of the person is necessary. He should
be informed about the correct work procedure. Rescue, resurrection and first aid arrangements
should be in ready condition for use in emergency. Approved PPE shall be used. Restore the
original condition after completion of the work.

18. Safety of Sampling Personnel :

This should be ensured by safe procedure and use of approved PPE.

19. Ventilation :
Adequate ventilation at all times in process area to avoid any harmful concentration.

20. Emergency Procedure :

Should be developed as prescribed in para-23 of the Schedule and must be rehearsed every three
months. They include identification of all possible emergencies (which should be reviewed every
year), arrangements for outside help for rescue, fire fighting and medical facilities, warning
arrangements (its effectiveness should be checked every month), alternate power supply, safe
close down procedure, evacuation of persons and its training to workers, information to doctors
and precautions against danger due to effluent. Deficiencies to be corrected. Ten percent workers
should be trained in the use of first aid fire fighting equipment. The chemical identity (with
antidote) should be furnished to the doctor for emergency or first aid treatment to exposed person.
For On-site and Off-site Emergency Plan see Part 7 of Chapter-19.

21. Dangers due to Effluents :

Gas evolution due to mixing of different effluents should be prevented. Effluents causing
poisonous gases should be trapped and rendered safe by independent drainage.

Part - III : Fire & Explosion Risks :

1. General:
Fire hazards area classification should be as per IS. Spark generating machines, equipment,
fittings etc. not permitted in fire prone area. Hot pipes either outside the plant or be protected.
Soles of footwear, wheels of trucks or conveyors and tools shall be of nonsparking type. Smoking
prohibited. Notices to that effect. Pipelines carrying flammable/ explosive substances shall be
protected, examined once a week and record kept of defects and repairs.

2. Static electricity:
Plant, machinery, pipelines, belt drives, receptacles of flammable liquids etc. shall be earthed and
humidity be regulated. Mobile tankers to be earthed before filling and discharge. Lightening
arrester shall be maintained where necessary.

3. Process heating :
Contact of flammable vapour and open flame should be prevented. Heating should be safe and
automatically regulated below danger point.

Fundamentals of Industrial Safety and Health 23- 22 Safety in Construction Industry

4. Leakage control:
Bund/dyke surrounding storage vessels of flammable liquids. Fire fighting appliances near such
vessels. Waste material contaminated with flammable substances be disposed off safely under
supervision.

5. Safety valves and Pressure gauges :

Be fitted on stills and vessels containing gas pressure above atmosphere and maintained well.

6. Fire fighting system :

Where workers exceed 500, trained fire fighting squad of more than 8 persons available at any
time and consisting of watch and ward personnel, fire pumpman, departmental supervisors and
trained operators for fire and emergency services is required, the squad personnel be provided
with protective clothing and equipment. Muster roll of duties be maintained. Telephones should
be inter-linked with pump room, main gates and storage area.

Part-IV : Toxic Risks :

1. Leakage & Drainage :

Construction to prevent, segregate or localise escape of toxic release. Bund, dykes and catchpits
below pipe joints to collect leakage. Drainage leading to collection and neutralisation or
treatment tanks for safe discharge.

2. Vessel covers :
Be provided to avoid physical contact. Fence height 90 cm. or more.

3. Exhaust arrangement;
Required on gas evolving processes and be interlocked with process control where possible. In
case of its failure, the process should automatically stop.

4. Work benches :
Of smooth impervious surface and be washed daily after work.

5. Waste disposal:
Non absorbable receptacle with tight fitting cover to collect waste or rejected material soiled with
toxic substance. It shall be destroyed by burning or other safe way under supervision. Empty
containers be cleaned before disposal.

Part-V : Special Provisions :

Here precautions have been prescribed for following specific processes- .

1. Nitro or Amino processes.

2. Chrome processes.
3. Use of Glass vessels.
4. Chlorate manufacture.
5. Use of plastic vessels and equipment.

Dust or fume control and antidote methylene blue injection are suggested for Nitro or Amino
processes.

Fundamentals of Industrial Safety and Health 23- 23 Safety in Construction Industry

 Exhaust draught, washing facilities, weekly inspection of hands and feet and skin ointments are
required for chrome processes.

Wire mesh covering and spillage removal are necessary for all processes in glass vessels.
Chlorate manufacture requires use of hard, smooth, non-combustible surface or vessels, water
showers and daily cleaned PPE.

Plant and equipment made from reinforced plastics should be standard (IS), strong against loads,
pressure tested by a competent person and not allowing over filling or over loading.

Part-VI: Welfare Amenities:

1. Washing:
One tap for every 15 workers with liquid soap and nail brushes. They should be separate for males
and females.

2. Special bathing:
Are required for workers engaged in processes of nitro or amino compounds, chrome, tar,
cyanide, cyanate or cyanogen compounds, bleaching powder, chlorine, nickel and its compounds
or their derivatives. The CIF has power to direct other industry also. 1 bathroom for 25 workers.
Bath necessary at the end of shift.

3. Mess Room:
Required for factories employing 50 workers or more with good ventilation, furniture, drinking
water and washing facilities.

4. Cloak room:
Two lockers for each worker, one for work clothing and another for personal clothing.

Part VII : Duties of workers :

Workers shall not make any safety device, guarding or fencing inoperative or defective. They
shall report malfunction or defect of machinery, equipment etc. immediately, use PPE, co-operate in
emergency duties, undergo medical examination and not do any unauthorised work to cause risk t
themselves or others.

Part VIII : Restrictions on young persons

The CIF may by an order in writing, restrict c prohibit employment of women and young person
below the age of 18, considering their health and safety aspect. Then such workers should be provide'
with alternate work not detrimental to their health c safety.

Refer following schedules also for specified chemical processes :

Schedule No. u/r

Process
102 GFR 114 MFR 95 TNFR
2 2 2 Electroplating
3 3 3 Electric accumulators
4 4 4 Glass manfacture
5 5 5 Grinding & Glazing of metals
6 6 6 Lead & lead compounds

Fundamentals of Industrial Safety and Health 23- 24 Safety in Construction Industry

 8 8 8 Air/steam blasting
10 10 17 Chromic acid or chromates
12 12 21 Acids or Alkalis
14, 22 14, 19 26, 30 Carbon disulphide
15 15 29 Pesticides
16 16 18 Compression of O2 & H2 by electrolysis of
water
18 - 19 Stone & free silica
21 21 23 Oils, fats and solvent extraction plants
24 - - Gas welding & cutting
- 18 25 Manganese & its compounds
- - 10 Cellulose spraying
- - 11 Graphic powdering
- - 13 Cashew-nut processing
- - 14 Coir & Fibre factories
- - 24 Fireworks & Match factories
- - 30 Rayon by viscose process

IS : See Chapter-18 exclusively for safety in chemical industry and its Part-5 for IS listed therein.

12 CLOTHING INDUSTRY

Garment making is an old and universal industry. Hazards are hand injuries, cuts, burns,
crushing, fire and chemicals. Preventive measures include :

1. Fire safety (see Chapter-13) and safe means of escape.

2. Good housekeeping (see Chapter-8).
3. First aid (see Chapter-26).
4. Guarding of circular knives of portable cutting machines, power presses, needle and drives of
sewing machines, under-bench shafting. Various types of needle guards and press guards (two
hand control not fully safe) are available.
5. Good earthing and ELCB of portable electrical power tools including irons.
6. Dust suppression and fume control of formaldehyde resin and toxic solvents.
7. Ample air space, good ventilation and temperature and high standards of illumination.
8. Well designed seats for normal posture and reducing fatigue of scapular, dorsal and lumber
muscles. Adjustable seats and backs are necessary where more than one shifts operate. Ergonomic
designs are safe.
9. Noise control in zip fastener chain production plant.
10. Pre and post employment medical examinations, lunch/rest rooms, washing and sanitary
facilities and
11. No exploitation of any kind where girls, women and illiterate workers are employed.

IS : Washing machine 6930, lockers – metal 3314, wooden 5923, clothing - conductive for live
working at 800 KV 13771, leather protective 6153, safety industrial 8990, stains removal 11210,
clothessize designation 10015, body measurement sizing systems 10397, collar-white, handloom 2715.

13 DAIRY PRODUCTS INDUSTRY

Fundamentals of Industrial Safety and Health 23- 25 Safety in Construction Industry

 Milk, cheese, curd, butter, ghee and milk powders are widely used. Their industrial manufacture
should include :

1. Machine guarding of separators, centrifuges (with interlocking), rotary churns with bar fencing
interlocked with churn drive unit, icecrushers, cheese graters, bottling or filling machines, nip
between conveyor drums and pulleys etc.
2. Safety of boilers, steam receivers and pressure vessels.
3. Toxic hazard control of refrigerant used. Respiratory and other PPE are necessary.
4. Non-slip floor, non-slip footwear, cleanliness, good housekeeping, fixed stairs and platforms with
hand railings and guarding of open vats and vessels.
5. Chemical hazard control for acids and alkalis, use of PPE, first aid and medical care.
6. Double insulation and earthing of electrical machines and tools.
7. Explosion relief vents and temperature control in milk spray drying chambers to avoid fire and
explosion.
8. Veterinary medical supervision, personal hygiene, good washing facilities to prevent animal
infectious causing brucellosis and bovine TB.

See Part 10.9 (Micro-organism Rules) of Chapter28 for some statutory provisions.

IS : Dairy- floor finishes 7956, equipment, cleaning and sterilising 5253, industry '- rubbers 6450,
tests 1479, effluents guide 8682, laboratories, layout 2981, thermometers, floating 1672, farms, cattle
sheds 6027.

14 ELECTRONICS INDUSTRY

The use of electronic items is day by day increasing in industry, at homes and at many places.
Their manufacturing should include:

1. Exhaust ventilation for fumes of lead, zinc, rosin etc. and also for molten-solder tanks.
2. Eye protection for organic peroxide hardeners and respirators for quartz flour, epoxies with
phenol compound and airborne concentrations.
3. Prevention of flammable or explosive mixtures of solvents and source of ignition.
4. Exhaust ventilation for printing process.
5. Acid resistant and non-slip flooring, exhaust ventilation, eye bath and PPE in etching processes.
Use closed containers for etching liquids.
6. Good industrial hygiene.

IS : Electronic apparatus, safety requirements 616, climatic and durability tests 589, .gas lighters
9000, equipment - environmental tests 2106, reliability testing 8161, 7354, safety in use , maintenance,
manufacture 11743, measuring apparatus, safety requirements 9858, weighing systems 9281, 11547,
buzzers 12825, flash apparatus safety 12274, flashers 13135.

Electronic ear protectors 9167, assessment of noise exposure 7194, radiation protection for X-ray
tube, radio transmitting equipment, safety requirement 10437,6970, 6567, safety code for radiographic
practice 2598, safety of data processing equipment 10422, Hand/foot contamination monitors 11869,
Fire hazard testing 11000, protection against ionising radiation 11868.

15 ELECTROPLATING INDUSTRY

Fundamentals of Industrial Safety and Health 23- 26 Safety in Construction Industry

 This electrochemical process of surface treatment uses chemicals and direct current source for
electroplating of many components to protect against corrosion, to improve surface properties and
decorative effects. Washing and galvanising are also carried out.

The electrolyte solutions may be acidic, alkaline o: alkaline/cyanidic. The safety measures include:-

1. Control against irritant and toxic chemicals acids, alkalis, dust, gases, fumes and vapouri of
organic solvents.

2. Control against electric current with good earthing.

3. Ventilation system to carry exhaust air at a low level and supply of fresh air from upper level

4. Local exhaust ventilation near mechanical cleaning, polishing and grinding. Ergonomic designs
are necessary. Aluminium dust must be collected in wet trap to avoid explosion.

5. Iron and aluminium should be ground in separate units.

6. Goggles, gloves, respirators and other PPE necessary.

7. Sucking off heavier solvent vapours from below (where they are condensed) near degreasing
baths which should be installed with 1 mt safety zone between the worker and the edge of the
bath. Bench ventilation is also necessary for the after treatment of degreased parts. Benzene
should not be used.

8. Protection against acids and alkalis in pickling process. Nitrous fumes and HF fumes must not be
allowed in workroom. Their proper exhaust is necessary. Water showers and eye-washers for
treatment of burns and acid-proof PPE necessary. The acid should be poured into water while
stirring continuously, not the other way.

9. Cyanide poisoning may be fatal by breathing or skin contact. The process must be in closed
condition. The first-aid measures must be ready. Removal of contaminated clothing, washing with
water and fresh air or oxygen treatment will be helpful. Lunch should not be allowed in work
room. Optimum hygienic conditions necessary.

10. Chromium plating can cause burns, ulceration, nasal perforation and eczematisation. Powerful
exhaust ventilation with maximum closing surface hood and acid-proof PPE are necessary.
Exhaust ventilation at the rim of the bath is most effective. Air extraction per cm 2 bath surface
should be @ 1800-2700 m3/h. Non skid floors or plastic duck-boarding, electrical safety (see
Chapter-11) and environmental and biological monitoring are necessary.

Statutory Provisions:

Schedules 2, 10, & 12, u/r 102, GFR are relevant. Summary of Schedule-2 is as under :

Applicability:

This substituted schedule is applicable to electrolytic process which means electrolytic plating or
oxidation of metal articles by the use of an electrolyte containing acids, bases or salts of metals such a
chromium, nickel, cadmium, zinc, copper, silver, gold etc.

Safety Measures prescribed:

Fundamentals of Industrial Safety and Health 23- 27 Safety in Construction Industry

1. An efficient local exhaust draught near vapour origin, preventing the vapour to enter into anyroom
or work place.
2. Child, adolescent or Women are prohibited to work at a bath.
3. Impervious floor. It should be washed daily.
4. Waterproof aprons, bibs, rubber gloves, rubber boots, chemical goggles and accommodation to
store and dry such PPE of the workers.
5. An undercover wash place or wash basin, one tap for five workers working at a time, with spacing
of 12 cms. per worker, waste pipe and constant supply of water.
6. Clean towels and soap etc.
7. Emergency shower with eye fountain.
8. Storage tank of 1500 litres clean water for above purpose.
9. Cautionary notice as prescribed.
10 Medical examination of workers by an employed doctor approved by the CIF. Pre employment
and fortnightly examinations and their records are prescribed. Barrier cream, ointment,
waterproof plaster, emergency cyanide kit etc. should be provided.
11. Medical examination by the certifying surgeon includes pre-employment and periodical six
monthly or yearly examination as prescribed. For use of chromium, nickel and cadmium, urine
test is suggested. Fitness certificate in Form No. 27. Health record in form No. 20. Unfit person
shall be given alternate placement. Re-employment in the same process if the CS declares him
fit.
IS : Electroolated coating- - silver 5925. 6267, 1959, 9530, aluminium 9844, brass 11773,
chromium 1068, 1986, gold 4252, 3266, lead 1992, nickel and chromium 4942, nickel 12393, 1809, zinc
and cadmium 9839, zinc 1880, 2290, 3027, 12519, Corrosion resistance test 9844, 5528, Local thickness
testing 3203, Glossary 3554, Equipment 2679, Industry, treatment of effluents 7453, Recommended
practice 3655, filter and powder 10472, mechanical polishing of metals 3656, copper salts 487, succinic
acid for electroless plating 9909.

16. FERTILISER INDUSTRY

Fertilisers are natural (manure) or artificial. Artificial fertilisers are produced in chemical plants
and they may be organic or inorganic,
nitrogenous, phosphatic, potash and trace element
fertilisers. In the warehousing stage, phosphate.
potassium-salt and other dusts are released. In
chemical processing plant, air pollution by toxic
gases (Fluorine compounds, H2SO4, NO, HCI, CO
and NH3, gases) and dust, high air temperature
and noise are noticed. Closed and efficient
ventilation is necessary. In finishing processes,
weighing, bagging and storing, gaseous emissions
and fluorine compounds are released. Phosphates
and other raw materials contain 10% or more free
silica which may cause pneumoconiosis. The dust
of soluble fertilisers causes irritation. The safety
measures include:

1. Mechanisation and automation of production processes, provision of remote control, careful

assembly and safe operation of equipment and heat insulation.
2. Process segregation and walls and floor covering to absorb fluorine compounds.
3. General ventilation, exhaust ventilation of enclosed plant, cleaning of exhaust air and waste water.

Fundamentals of Industrial Safety and Health 23- 28 Safety in Construction Industry

4. Education and personal hygiene.
5. Use of PPF and safety showers.
6. Safety and sanitary supervision.
7. Pre and post medical examination including radiographs of the locomotor system and lungs.

IS : Fertiliser - Glossary 1304, sampling and tests 6092, bagged, handling and storage 5985,
mixtures 7863, 9024, effluents - tolerances 2590, treatment and disposal 9841, application equipment
glossary 9855, Metering mechanism plate type 12599, feed roller type 12613, Urea ammonium phosphate
based 8359, nitrophosphate based 7131, seed drills 6316, 6813, Phosphatic fertiliser industry. Limits of
emissions 8635. -

17 FIRE WORKS AND MATCH FACTORIES

There are two types of matches, strike- anywhere matches and safety matches which strike only
on friction slips. Wood for its splint and phosphorus for its ignitable head pose fire and explosion
hazard. There are dust and fume hazard also. Employment of more number of children in poor working
conditions and exploitation increase more hazards. The safety measures include:

1. To prevent fire and explosion risk, manual handing should be replaced by mechanical handing,
sources of ignition and friction should be eliminated, fire-resisting PPE should be provided.
2. Good house keeping , gangways and exits.
3. Guarding of guillotine, splitting knives, rollers, printing press and other machinery.
4. Prohibition of white phosphorus. Use closed containers.
5. Good general ventilation and local exhaust ventilation near weighing, mixing splint polishing
drum and where chromium or lead compounds are used.
6. Strict cleanliness, sanitary and washing facilities for all workers and cloakroom, mess room or
canteen to be separated from process room.
7. Good sitting arrangement should be provided.
8. Only adult workers should be employed.

IS : Fireworks - aeroplanes 12975, rockets 12980, match box - paper 3303, safety 2653, 10373,
10374, 9600, log 1140, Match industry, animal glue 13254.
In December 1999, the Central Government declared prohibited production, sale and use of such
fire works which cause noise>123 dB within 4 mt from the point of their firing.

18 FOOD INDUSTRY

Food industries include treatment, preparation, conversion, preservation and packaging of

foodstuffs. Women employment varies from 20% to 55%. The industry depends upon seasonal raw
materials of vegetable or animal origin.. The processes are handling and storage of raw materials,
extraction, crushing, separation, centrifuging, filtering, processing, fermentation, cooking, dehydration,
distillation and preservation by high or low temperature processes. High-temperature processes include
cooking, sterilisation (steaming in autoclave), pasteurisation, smoking and .dehydration. Low temperature
processes include cold storage, freezing and deep freezing.

The safety measures include :

1. Nonslip and dry floor.

2. Good housekeeping.
3. Covered pits and floor openings.

Fundamentals of Industrial Safety and Health 23- 29 Safety in Construction Industry

4. Good ladders, safety belts, lifelines and safe means of access.
5. Good lighting and ventilation.
6. Safe use of knives and cutters.
7. Treatment of burns and scalds from steam and hot substances. Insulation of hot surfaces.
8. Prevention of explosion of boilers and autoclaves.
9. Electrical safety.
10. Control of airborne concentrations, dusts and explosive mixtures of gas or oil fired ovens.
11. Prevention of health hazards due to caustic, refrigerants, infections and parasitic diseases spread
by animals and dermatitis and allergies by organic products. See Part 10.9 of Chapter-28.
12. PPE for protection in cold storage.
13. Personal and industrial hygiene.
14. Good sanitary and washing facilities and Guarding of typical machinery used.

IS : Food poisoning bacteria 5887, 7688, cereals warning 1656, Foodgrain and pesticides residues
sampling 11380, Parathion residues 5952, malathion residues 5863, monocrotophos residues 11374, Safe
use of -PVC 7288, polyethylene 7277, styrene polymers 7961, Food colours 5346, tests for dye content
6120, dimethoate residue 11021, Sampling and tests 1699, sensory evaluation glossary 5126, effect of
packaging 8639, food yeast 3839.

See Part-7 also.

19 GLASS INDUSTRY

Types of glasses are soda-lime-silica glasses, lead potash silica glasses and borosilicate glasses.
Regenerative or recuperative furnaces work upto 1500°C. After melting, other processes are annealing
(controlled cooling) manual and mechanical blowing, pressing, rolling, float glass process, grinding and
polishing, surface modification, pre-stressing for toughened glass and bonding for laminated glass.

Hazards are due to glass breaking and flying, silica, lead alkaline dusts, fuel and exhaust gases,
heat radiant energy, glass blowing, heat cataract and noise.

Safety measures include :

1. Mechanisation and automation.
2. PPE against cut injuries, dust, fumes, gases, heat and noise.
3. Good housekeeping and regular monitoring.
4. Exhaust ventilation (for room and furnace).
5. Automatic weighing, mixing and transfer by enclosed methods.
6. Protection against HF fume by polyethylene containers and siphon transfer, PPE, washing facility
and magnesium oxide paste.
7. Protection against high heat by screening, water cooled undersuit beneath reflective asbestos
clothing.
8. Medical supervision for lead and other poisoning.
9. First aid and X-ray photograph arrangement to detect glass penetration and
10. Good washing facilities.

Statutory Provisions:

Summary of Scheduler, Rule 102, GFR is given below:

Fundamentals of Industrial Safety and Health 23- 30 Safety in Construction Industry

 Efficient exhaust draught, lead compound and suspension are defined. Exhaust draft is required
for mixing of raw materials to form a 'batch', dry grinding, glazing and polishing of glass article,
processes giving HF or NH„ vapours, pots or furnace mould processes and all processes involving dry
lead compound. In such processes employment of women and young persons is prohibited.

Floors mid workbenches should be smooth and impervious to water, cleaned daily and well
maintained where lead compound or silica dust are manipulated.

Other safety measures include safe handling of HF (cylinder made of lead), no food, drinks etc. in
workrooms, PPE, washing facilities and medical examination - pre employment and then at every month,
with record in Form No. 20.

IS : Glass - Glossary 1382, packing 6945, safety 2553, toughened 6180, sheet transparent 2835,
tableware 1961, tubing for laboratory 7374, thermometers solid stem 2480, protector for tubular gauge
5428, condenser 6052, containers - thermal shock test 11930, vertical load test 11539, electrode for direct
reading pH meters 6804, glass fibre chemical resistant test 10661.

20 HAZARDOUS CHEMICALS AND PROCESSES

See Chapter-18 for safety in chemical industry and Part-10.8 of Chapter-28 for statutory
provisions on hazardous processes.

Statutory Provisions:

Hazardous process is defined in section 2 (cb) of the Factories Act, a list of 29 hazardous process
industries is given in the 1st Schedule and detailed provisions are given m Chapter-4A (sections 41A to
H) of the Art

See foregoing part II of this chapter for general safety provisions for 'Chemical Works' also
applicable to hazardous chemicals and processes.

The Central Government u/s 6, 8 and 25 of the Environment (Protection) Act made the
Manufacture, Storage and Import of Hazardous Chemicals Rules 1989 (See Part 10.8 of Chapter-28).
Then similar Rule 68J was added to the Gujarat Factories Rules 1963 w.e.f. 15-2-95. It was substituted by
Notification dated 30-6-2004.

Now sub-rules of rule 68-J, GFR are as under :

Definitions (Subrule-I)

Subrule-I defines hazardous chemical, industrial activity, isolated storage, major accident,
pipeline and Schedule.

Disclosure of Information (Subrule-2)

1. This provision is applicable to an industrial activity of hazards chemical mentioned in Part1 'or II
of Schedule-1.

2. MSDS specified in Schedule -5 should be prepared for hazardous chemical. It should be shown to
workers on request.

Fundamentals of Industrial Safety and Health 23- 31 Safety in Construction Industry

3. Labels on containers of hazardous chemical should identify content, name and address of the
manufacturer or importer and physical and toxicological data.

Duties of Inspector (Subrule-3)

The inspector shall inspect at least once in a year the industrial activity or isolated storage, send
annual status report and check major accident, site, safety report, safety audit report, onsite and offsite
emergency plans.

General Responsibility of Occupiers (Subrule-4)

1. It is applicable to an industrial activity of hazardous chemical mentioned in part I or II of
Schedule-1 and also to isolated storage containing threshold quantity (or more) mentioned in
column-3 of Schedule-2.
2. Identification of major accident hazards and steps to prevent or control them are necessary.
Persons working on site should be given ' training and equipment including antidotes necessary.

Notification of Major Accident : (Subrule-5)

1. Inspector and the CIF should be informed within 48 hours of such accident in Schedule-6.
2. The CIF shall inform the DGFASLI and the Ministry of Labour through proper channel.

Application of Subrules 7 to 13 : (Subrule-6)

Subrule No. Apply to threshold quantity in

(a) 7,8, 12 and 13 Sch- 3, Column – 3 (excluding, isolated storage)
(b) 8 to 10 Sch.-3, Column – 4(excluding, isolated storage)
(c) 5 and 6 Sch- 2, Column -3 (to isolated storage)
(d) 8 to 12 Sch -2, column – 4 (to isolated storage)

Notification of site (Subrule-7)

The CIF should be informed in Schedule -7 at least 3 months before commencing such activity. If
quantity of chemical mentioned in column 3 of schedule-2 & 3 exceeds the threshold quantity, it should
also be informed subsequently.

Report of the Updated information (Subrule-8)

Information sent as above shall be updated and subsequent updated report shall be sent to the CIF.

Safety Report and safety Audit Report (Subrule-9)

No industrial activity, to which this sub-rule applies, will be undertaken unless a Safety Report is
sent in Schedule-8, three months before commencing that activity. Safety Audit report should be sent
subsequently. Frequency of safety audit report-internally every year and externally two years.

Updating of Safety Report (Subrule-10)

Every 3 years updated safety report shall be sent.

CIF can ask further information (Subrule-11)

Fundamentals of Industrial Safety and Health 23- 32 Safety in Construction Industry

 CIF can ask further information regarding safety report or safety audit report.

On site Emergency Plan ( Subrule-12)

An occupier carrying an industrial activity to which this sub-rule applies shall prepare and submit
to the Inspector and the CIF an On site Emergency Plan in Sch-8A and rehearsal at every 6 months. For
its details see Part 6.2 of Chapter-19.

Information to the persons likely to be affected (Subrule 13)

The occupier shall inform persons likely to be affected the nature of major accident hazard and
'DOS' and 'Donts' about it.

Disclosure of Information (Subrule-14)

This is regarding information to other person and his obligation.

IS : See Part 5 of Chapter 18 on Chemical Industry. Hazardous Chemicals - glossary 4155,

classification 4607.

21 FLAMMABLE LIQUIDS AND GASES

See Part 8.3.1 and 8.3.2 of Chapter-18 and Schedules 7, 13, 14, 16, 19, 20, 21, 22 and 24 u/r 102
of the Gujarat Factories Rules for statutory provisions pertaining to flammable liquids and gases.

As defined under MSIHC Rules highly flammable liquids and gases are classified as –

1. Flammable gases (LEL upto 13% or explosive range 12%).

2. Extremely flammable liquids (FP<23 °C, BP<35 °Q.
3. Very highly flammable liquids (FP<23 °C, BP>35 "Q.
4. Highly flammable liquids (FP between 23 °C to 60"C)and
5. Flammable liquids (FP between 60 °C to 90 °C).

Difference between heat generated by the ignition source and heat generated by the burning
material is called the flammability index. This index of combustible material ranges from 0.5 to 2.1 and
that of highly flammable exceeds 2.1.

From flammability point of view, substances having melting (or dew) point above 50 °C are
considered as liquids and those having saturated vapour, pressure of 0.3 Pa or more at 50 °C are gases.

Properties of flammable substances are flash point, fire point, auto-ignition temperature,
flammable or explosive limits (range), maximum explosion pressure, maximum safe gap, minimum
ignition energy, minimum extinguishing concentration, rate of combustion, rate of total combustion, rate
of heating and type of reaction.

For the detailed definitions of above properties and evaluation of flammability of solids, liquids
and gases, reference No. 1 at the end of this chapter may be studied.

Hazards and Controls :

Fundamentals of Industrial Safety and Health 23- 33 Safety in Construction Industry

 Highly flammable liquids need low energy ignition source. Flammable gases are like boiling
vapours (owing to their boiling point < 20 °C)

Therefore both these substances will ignite immediately on contact of a spark or static charge.
Hence precautions mentioned in Section-37 of the Factories Act must be strictly followed. These
provisions prescribe -

1. Effective enclosure of plant, machinery or process.

2. Removal or prevention of accumulation of flammable dust, gas, fume or vapour.
3. Exclusion or effective enclosure of all possible sources of ignition (this includes static electricity).
4. Explosion relief devices (vents, baffles, chokes etc.) to restrict the spread and effects of explosion.
5. Safety precautions before opening any part or machinery, such as stopping (isolation or blinding)
of inflow of flammable substance, reduction of pressure inside etc.
6. Prohibition of welding, cutting, brazing etc. on vessel, tank etc. containing flammable substance
without necessary precautions.

Statutory Provisions

Schedule 13 u/r 102, GFR, Sch.23 u/r 114, MFR and Sch.31 u/r 95, TNFR prescribe statutory
requirements. Their abstract is as under (G=Gujarat, M=Maharastra & TN=Tamilnadu):

Sch.l3, Rule 102, GFR :

This is regarding manufacture of bangles and other articles from cinematograph film and toxic
and inflammable solvents.

Here 'toxic inflammable solvents' mean solvents like acetone, tetrachloroethane, alcohol,
denatured spirit, phenol, amylacetate, butyl acetate, diacetone and such other substances which in the
opinion of the CIF are toxic and inflammable.

Statutory provisions include -

1. Prohibition to employment of woman and young persons in the storage or process of above
chemicals.
2. Medical examination - first within 7 days of the employment and then every month. Record in
Form No. 20.
3. Protective clothing including apron and head-coverings.
4. Efficient ventilation in workroom.
5. No smoking and no source of ignition.
6. Flameproof electrical installation and fittings.
7. Smooth and impervious floor and to be washed daily with water.
8. 10 minutes washing time before each meal and before the end of the day's, work.
9. Washing, bathing, cloak-room and mess-room facilities.
10 Fire-fighting appliances, means of escape in case of fire and doors/windows to open outwards
readily.
11 Cautionary notices regarding dangers to workers. Contents to be explained to illiterate person
carefully.

Sch.23 u/r 114 MFR and Sch.SI u/r 95 TNFR :

This is regarding highly flammable liquids and flammable compressed gases.

Fundamentals of Industrial Safety and Health 23- 34 Safety in Construction Industry

 Here 'highly flammable liquid' means that specified u/s 14 & 15 of the Petroleum Act, 1934 and
which gives off flammable vapours below 32 °C.

"Flammable compressed gas' mean» that defined u/ s 2 of the Static and Mobile Pressure Vessels
Rules, 1981.

Statutory provisions include –

1. Safe storage in a fixed tank or closed vessel or a room of fire resistant construction.
2. Enclosed system of pipes, pumps etc. so as to avoid leak or spillage.
3. Leakage shall be contained, drained off or diluted to prevent flammable air mixture.
4. Exclusion of source of ignition by flameproof electric apparatus, prevention of static charge, no
footwear with steel or iron, belts without iron fasteners and prevention of ignition sources such as
open flames, sparks, hot surface, heat generating reaction and radiant heat.
5. Prohibition of smoking.
6. Fixed and portable fire fighting systems, materials and procedures as prescribed by IS.

IS : Flammable gases and vapours classification 9570, Flammable liquids detection, storage,
construction safety 10386, Flammability test for aerosol products 8469, cables 10810, flame spread of
products 12777, flame resistant suit 7612, flame photometer 8651, flame safety lamps, gas testing 7577,
Flameproof - AC motors for mines 3682, electric lighting fittings 2206, enclosures of electrical apparatus
2148, transformers 11333, Compressed - oxygen 309, hydrogen 1090, argon 5760, carbon dioxide 307,
nitrogen 1747, solvent - for paints 82, insulating varnishes 10026, petroleum hydrocarbon 1745.

See also Part 5 of Chapter-18.

22 LEATHER INDUSTRY

Leather is the skin of animals when tanned and prepared for human or industrial use. Leather
processing includes cutting and incision, chasing, moulding, embossing, hammering, mosaic formation,
trimming, bonding, stitching and dyeing. Industrial safety measures include :

1. Benzene and any aromatic solvents containing benzene should be replaced with substances in the
aliphatic series.
2. Toxic concentrations should be controlled by efficient exhaust ventilation.
3. As the solvents may produce fire and explosion, flameproof electric fitting and elimination of
sources of ignition are necessary.
4. Dyeing operations should be fully mechanised or enclosed to avoid human contact.
5. Personal protective equipment.
6. Medical check-ups.
7. Guarding of machinery and safe use of knives and hammers etc.

Statutory Provisions:

Summary of Schedule-10, Rule 102,, GFR, Sch.9 u/r 114, MFR and Sch.9 u/r 95, TNFR on
liming and tanning of raw hides and skins and incidental processes is given below :

Cautionary notices regarding Anthrax, Chrome ulceration and the occupational diseases listed in
the 3rd Schedule of the Act, are compulsory.

Fundamentals of Industrial Safety and Health 23- 35 Safety in Construction Industry

 Rubber gloves and boots, aprons and leg covering to workers working with chrome solutions or
lime work and other PPE to those handling hides or skins are necessary.

Washing facilities of one place for 10 workers, one wash basin-for 10 workers, mess room and
cloak room are required. Foods and drink in work rooms are prohibited. Hands of workers coming in
contact with chrome solutions shall be checked twice a week and suitable ointment and waterproof
plaster shall be kept in a box readily available.

IS : Leather - glossary 1640, clothing protective 6153, garments 12718, chromed buff calf skin
8121, apron 3446, chemical testing, chrome- belt lace 575, high altitude gloves 5866, footwear sampling
2051, gas meter diaphragms 9155, leg guard 3946, oil seals and washers 3020, gauntlets - for steel
workers 2574, mittens for steel Workers 2575, welders 2573, harness 580, belting for power
transmission 2240, round for small machines 2241, V-open ended, cogged 10022, endless flat for lenix
drive system 12854, hydraulic 581, loom-pickers 8546, picking band 1225, shuttle cock caps 4102, laces,
footwear 7721, Safety-belt & strap, lineman's 3521, boots for miners 1989, boots for metal industry 3737,
shoes for women miners 11225, footwear with moulding sole 11226, 5677, industry effluent 5183, lining
3840, polish wax emulsion 6045, sampling 5868, sandal for men 6493, sole 579, boards for insoles 5867,
shoes non-slip 11543, leather cloth vinyl coated fabric 1259, leather roid for electrical purposes 4819,
leathers 3840, chemical testing of leather 582, physical testing of leather 5914, utility glove 11230,
slickers for leather industry 5712.

23 PAPER INDUSTRY

Paper is a thin felted matrix of interlacing cellulosic fibres made from wood pulp or rags, straw
and grass or waste paper.

In making paper, first raw material from wood pulp, west paper or grass is cut in to pieces. Then it
is soaked in water to make pulp. Necessary additives and bleaching agents like C1 2 or H2O2 are passed
through the pulp to make it white. It is passed through many tanks and pulper machine. Then
homogenous pulp is passed through paper mill where it is run on the felt through wet and dry (hot)
processes. A paper film is formed as a result of this process in the paper machine. Then continuous paper
is wound or reel and a papci roll is formed. The roll is removed from the re-winder machine and sent to
the cutting department. There if is cut in to the required sizes and packed in bundles.

The safety measures should include :

1. Nip guards on various rolls and felt nips of drying and re-winders etc. Interlock guards for the
whole in running nip with additional side guards, efficient doctor blades, air feeds, belt feed and
well designed hand tools are necessary.
2. Manual straightening of paper should be replaced by mechanical straightening.
3. Sufficient stopping and breaking pushbuttons i.e. switches.
4. Operation with moving machinery at slow speed.
5. Automatic lubrication instead of manual while machinery is in motion.
6. Interlocked door on hopper of the baling press.
7. Pulpers should have strong fencing (railing) to prevent fall into the deep vessel and interlock door
near feed point.
8. Interlocked or photo cell guards on guillotine cutters and slitting machine.

Fundamentals of Industrial Safety and Health 23- 36 Safety in Construction Industry

9. Keirs, digesters, dryers and boilers should be fully closed under pressure and Rule 61, GFR
should be strictly followed. Safety valve, pressure reducing valve or regulator, pressure gauge
etc. should be well functioning.
10. Digester drives should be properly locked so that they may not rotate while charging or
discharging. Their start-switches should be with keys and properly identified.
11. Steam pipes should be lagged to prevent burns.
12. Bridges and walk ways over and along side the machine should be protected with double railing,
toe-boards and non slip surfaces to prevent falls into the machines.
13. Effective fencing at all points where there are chances of falling on moving-machinery or into
pits.
14. Adequate stock and use of lifting machinery.
15. Good drainage of wet flooring and cleaning thereof.
16. Guards on straw cutter drives and beaters. Hopper feeder for straw or grass cutter essential.
17. Railing around feed opening over digesters.
18. Guards on grass-beaters and cutters.
19. Guards on all drives, gears, couplings, pulley belts etc. of all machineries.
20. Locking of electric switches where accidental starting may cause accidents.
21. Fencing or guarding on pulper chests, agitator tanks and pump-motor sets.
22. Test all lifting machinery u/r 60 GFR and maintain form No. 8 and 10.
23. Exhaust blowers of steam dryers should run efficiently.
24. Guard of fly-knife (rotary cutter) should be interlocked. It should not open when cutter is moving.
25. Exhaust ventilation near steam exposures or hot environment.
26. Sufficient lighting in congested areas.
27. Enclosures, barriers and absorptive or reactive silencers to reduce high noise levels.
28. Suction and closed ducting to convey flying dust.
29. To prevent chemical hazards of soda, sulphate and sulphite, use hooded ventilation to vent off
steam, HF, SO2, mercaptans, etc. Use mechanical agitation and spraying.
30. Prevent chlorine and ammonia hazards in bleach plant. See Part 8.6.1, 8.6.2 and 17.3 of Chapter-
18 for chlorine & ammonia safety. Bleaching should be carried out in a closed system at a
negative pressure.
31. Treatment for caustic burns.
32. Many chemicals used are toxic, flammable and explosive for which effective ventilation, careful
handling and fire control are necessary.
33. Good washing facilities, cloakrooms and lunchrooms are necessary.
34. Speedy removal of waste paper, pulp, spillage, dusts and good housekeeping are essential.

IS : Glossary of terms relating to paper and packaging 4261, 4661, 7186, relating to paper sacks
9028, terminology 7186, methods of test for pulp 6213 (Part I to 21), methods of sampling and test for
paper and allied products 1060 (Part I to 3), methods of test for corrugated fibre board 7063 (Part I to 4),
methods of test for smoothness/roughness of paper 9894, Axial (end to end) compression strength of
composite cans, tubes and cores, method of test 13975, method of end blow-off pressure test for
composite cans 13976, corrugated fibre board boxes for packing and transportation 13228, for exporting
glass jars and bottles 9313, for packaging of apples 11844, for packing soaps 10176, fibre board drums
7601, general purpose packing/wrapping paper 6615, grease proof paper 6622, ice-cream cups and lids
10177, kraft paper 1397, packing paper, waterproof bitumen laminated 1398, aluminium foil laminates
for packaging 8970, waxed paper 3962, 3963, 7162, 9988, alkali resistant paper 3673, base paper - for
carbon paper 3413, for tracing paper 11687, for waxed paper 2991, blotting paper 1396, cover paper
6956, hand made drawing paper 3064, map printing paper 12765, newsprint paper 11688, paper for
permanent records 1774, paper sizes 1064, sizes of envelopes 3338, tracing paper 8431, tissue paper
8460, printing paper 1848, cellulosic paper for electrical purposes 9335 (Part I to 3), 2189, paper clip
5650, Cuttings 4356, germination 6671, insulated leadsheathed cables 3961, insulation, tear resistance

Fundamentals of Industrial Safety and Health 23- 37 Safety in Construction Industry

10810, photographic 6139, 6650, 10329, sizing, gelatine for 11227, stationery for schools 5195, top
gummed 4185, teleprinter page roll 9031, tray 3791, wastage and spoilage guide for printing industry
12000, writing and printing 1848, for computer 12766, for data processing 10557, paper and board
impregnated 5134, paper rolls, sizes, 13075, paper green dehydrated 9486.

24 PESTICIDE INDUSTRY

Pesticide is a chemical used to destroy an organism detrimental to human interest. It includes

insecticides, fungicides, herbicides, rodenticides, bactericides, miticides, nematocides, moUuscicides.
They are generally halogenated (Cyclodienes, Bischlorophenyls, Cycloparaffins, Organo-chlorines
and Chlorinated terpenes) or Organophosphorus (Parathion, malathion, TEPP, OMPA, DDVP, abate,
ciodrin etc. ) type. They are classified as extremely hazardous, highly hazardous, moderately hazardous,
slightly hazardous etc. For these classifications and their details including Lethal Dose values see
Reference No. 1 given at the end of this Chapter. Strict safety rules are necessary during their processing,
handling, packaging etc. Exhaust ventilation and use of PPE are essential.

Statutory Provisions:

Schedule 15, Rule 102, GFR, Sch.l5, Rule 114, MFR and Sch.29,Rule 95, TNFR give statutory
provisions for manufacture and handling of dangerous pesticides listed in Appendix-1 to that Schedule.
Appendix-11 gives cautionary placard.

The measures include prohibition of employment of women and young persons, air space of 500
3
m or more per person, efficient exhaust draft on charging, discharging, blending and powder or liquid
preparation, sound and sloping floor with gutters and drainage, daily washing, workbenches of stainless
steel, waste container with lid and waste disposal by burning, safe disposal of empty containers, no
manual or direct handling, protective clothing and their daily washing, medical facilities including doctor
and antidotes and medical examination - pre employment, quarterly examination and record in Form 20,
GFR additional rest interval of 10 minutes before each meal and before the end of the day's work,
washing and bathing facilities with at least 50% bathrooms and 1 place for 5 workers with clean towels,
soap and nail brushes, prohibition of food and drink in workrooms, cloak room for clothing and PPE,
mess room with incharge person and prior permission o? the CIF to start manipulation of a new pesticide
i.e. not listed in Appendix 1.

Sch.l5, u/r 102, GFR defines "pesticides" as agents used for the purpose of destroying or arresting
the growth or increase of harmful organism and defines "dangerous pesticides" as those listed in
Appendix-1 as under:

Appendix-1, List of Dangerous Pesticides

(Under GFR & MFR both)

Prathion Mercury compounds

Diazinon Methyl bromide
Hexaethyl tetraphosphate Cyanides
Tetrathyl pyrophosphate Chlordane
Tetraethyl ditripyrophosphate Endrin
Demeton (systex) Aldrin
Schradan (OMPR) Dieldrin
Para-Oxon (E. 600) Texaphene

Fundamentals of Industrial Safety and Health 23- 38 Safety in Construction Industry

Methyl Parathion Dinitro-o-cresol
Dimefox Arsenical compounds
Sulphotepp Cryloite
EPN Pentachlorophenol
Nicotine or its compounds Carbojuran
This list gives commonly better to refer the exhaustive Insecticides Act. used pesticides. It is list
u/s 3(e) of the

Sch.l5, u/r 114, MFR, defines "dangerous pesticides" as those defined in Sec. 3(e) of the
Insecticides Act 1968 or any other substance declared as such by the CIF in writing. List of Insecticides
u/ s 3(e) of the Act is very long with addition from time to time.

Sch.29, u/r 95, TNFR does not give Appendix1 i.e. a list of dangerous pesticides but defines
dangerous pesticides' as any product proposed or used for controlling, destroying or repelling any pest or
for preventing growth or mitigating effects of such growth including any of its formulations which is
considered toxic under and is covered by the Insecticides Act, 1968 and the rules made there under any
other products as may be notified from time to time by the State Government.

"Manipulation" includes mixing, blending, formulating, filling, emptying, packing or otherwise

handling.

Appendix-11, Cautionary Placard is similar in all above three State Rules and is reproduced
below:

Cautionary Placard

1. Pesticides are generally poisonous substances.

2. Therefore in rooms where these are handled(a) do not chew, eat, drink Or smoke; keep food or
drink away from pesticides. (b) use the protective wear supplied e.g. gloves, aprons, clothes,
boots, etc.
3. Before meals or when any part of the body has come in contact with the pesticides, wash with
soap and water.
4. Before leaving the factory, take a bath and change your clothing.
5. Do not use any container that has contained a pesticide as a pot for food or drink.
6. Do not handle any pesticide with bare hands; use a handled scoop.
7. Avoid spilling of any pesticide on body, floor or table.
8. Maintain scrupulous cleanliness of body and clothing and of your surroundings.
9. In case of sickness like nausea, vomiting or giddiness, inform the manager who will make
necessary arrangements for treatment.

Effects and Controls :

Pesticides and agrochemicals enter into the body through inhalation, ingestion or skin absorption.
They are classified as toxic, harmful, corrosive, irritant, flammable, explosive or oxidising. Toxicity is
mostly denoted by LD,, or LC,, values. All agrochemicals should be labelled, transported safely and
correctly stored in a room (locked and cool). Containers should be opened only after wearing correct
respirator (positive air pressure), neoprene or plastic hand gloves, aprons, boots etc. Protective clothing
are always essential while handling pesticides. Inhalation of vapour should be avoided. Contact with skin,
eyes and clothing should also be avoided. Contaminated clothing should be immediately changed, the
entire body .should be thoroughly washed with soap and water. After working with pesticides, shower

Fundamentals of Industrial Safety and Health 23- 39 Safety in Construction Industry

bath should be taken and clothing should be changed. Contaminated equipment should be cleaned with
soap or soda ash.

Local exhaust ventilation on filling line must be effective.

Types of effects may be acute (immediate) or chronic (prolonged or slow delayed). Some
common symptoms are - dizziness, headache, shaking and weakness. More toxic effects may cause
convulsions, irrational behaviour or unconsciousness.
First-aid treatment includes - removal of affected person to a safe, clean and airy place, washing
of the part affected and to put the person in recovery position (slipping on shoulder). On swallowing,
vomiting should be induced if person is in consciousness. Medical charcoal and plenty of water may also
be 'given.

Effect of organophosphorous pesticides is to reduce cholinesterase level in body and it can be

noticed by pin-point in pupils (eyes).

Blood cholinesterase activity test should be carried out every 15 days. If the level is found less
than 62.5%, the worker must be transferred to another place where no exposure is possible. After medical
treatment and. safe report he can be put back to his plant. But meantime the engineering controls should
be provided or revised to eliminate the exposure. Leakage and spillage must be removed. Defect in PPE
should be checked and removed.

An Office Circular dated 27-7-1995 of Factory Inspection Office, Bharuch, sent to pesticide
factories, seems to be more important and suggests following safety measures :

1. For filling bottles or small containers of liquid, granules or powder, automatic filling machines
with closed chamber and attached local exhaust ventilation must be used. Weighing, plugging and
sealing operations and conveyor movement should also be automatic and under suction chamber
so that a worker has not to touch any thing and no spillage, vapour or dust shall touch his body.
2. To fill barrel or big container a chamber with exhaust hood and ventilation should be used.
3. To contain or collect leaking liquid small bund and pit shall be provided.
Spilled pesticide should be neutralised or washed with dry clean cloth and stored in a dust-
bin with spring-lid. Then it should be safely disposed or burnt out.
4. Workers engaged to shift, move, clean or pack the filled (plugged) container or to clean any
spillage, shall be given goggles, long sleeved shirt and pent, good quality rubber hand gloves,
waterproof suit or apron, gumboot and air-line respirator. Safety showers and bathrooms shall be
provided.
5. Illiterate, untrained and temporary contract workers are exposed to more risk. Therefore such
training should be given to them so that they can read or understand the necessary precautions.
6. Pedestal or positive air fan removes the vapour or dust from one worker to another. Therefore it
is inadvisable. Exhaust or negative air suction and air-line respirators are the effective
remedies. Exhaled air should be passed through carbon bed filter or effective absorber and final
vent discharge should be within safe limit.
7. Regular air monitoring at work place, ppm record and leakage checking are necessary.
8. A record of full name, address, signature, date of joining and photograph of all the workers at the
time of first employment are useful to detect cases of delayed effects or after-service effects.
9. If pre-employment and subsequent medical examination shows blood cholinesterase level less
than 62.5%, that worker should not be employed in pesticide work. If RBC level is also low, the
worker should be kept away for 3 months from such process. Sufficient stock of PAN, Atropine
etc. (antidotes) should be kept in the factory first-aid centre.

Fundamentals of Industrial Safety and Health 23- 40 Safety in Construction Industry

10. The workers must be aware that in case of symptoms (dizziness, headache, vibration, vomit etc.),
which doctor they have to approach. They will follow the medical advice.
11. In each shift, qualified and trained supervisor shall strictly supervise the working conditions, work
habits, methods, use of PPE, washing, cleaning and no smoking, eating or drinking in work area.

Specified medical treatment is as under :

1. In case of skin contact of-organo-phosphorous, it should be immediately treated with solution of

5-10% ammonia or 2-5% chloramine.
2. Give injection Atropine sulphate according to age, 2 to 4 mg intravenous or intramuscular.
Continue this injection every 5 to 10 minutes till pupils size and heart beats become normal.
3. Give injection PAM (2-Pyridine Aldoxime Methochloride) in glucose slowly. Toxogonin is a
condensation product of Pyridine aldoxime and dichlorodimethyl ether.
4. Maintain fluid and electrolyte balance.
5. Give antibiotic medicine to prevent secondary infection.
6. Give Frusemide if lungs are swallowed or water filled.
7. If breathing stops, artificial respiration must be tried till doctor comes. The patient should be kept
in a cool and quiet place. Give oxygen if difficulty is in breathing. If breathing trouble is more, the
victim should be shifted to hospital and put on ventilator.

Personal hygiene - to wash hands and mouth before and after lunch and bathing and changing
clothes at the end of the work - is highly essential.

See Part 4.1 & 4.2 of Chapter-28 for Insecticides Act & Rules.

IS : Handling cases of pesticide poisoning 4015 (Part I & 2), malathion- safety code 10872,
technical 1832, phorate G 9359, methyl parathion 10630, benonyl 13786, dodine 13784, diflubenzuron
14185, 14186, pesticide common names 885, determination of metalaxyl residues 14161, methods of test
6940, Residues determination in agriculture, food commodities, soil and water - 13830, 13831, aldicarb
10629, aldrin, dieldrin, aptafol 13245, in food 5863, organochlorine in tobacco products 11820, sampling
11380, solid and liquid packing requirements 8190 (Part I to 4), solid packaging 6604, zinc phosphide
9278, aluminium phosphide 9279, kitazin 13788 to 13790.

Packing containers - HDPE bags 8069, polyethylene 9754, aluminium bottles 9503, aluminium
containers (5 litres and above) 9445, tinplate cans 9992.

25 PETROCHEMICAL INDUSTRY

This is relatively a recent industry. The plants are modern, mostly automatic and totally enclosed.
It uses gaseous, liquid or solid hydrocarbons. Toxic and flammable exposures and high pressure- high
temperature reactions pose health, fire and explosion hazards. Proper FFE and PPE should be used. Pre
and periodical medical examinations are necessary. Other aspects similar to chemical industry (see
Chapter 18).

Statutory Provisions:

Summary of Schedule 7, Rule 102, GFR, Sch.7, Rule 114 MFR and Sch.7, Rule 95 TNFR is as
under:

Fundamentals of Industrial Safety and Health 23- 41 Safety in Construction Industry

 It is applicable to generation of gas from dangerous -petroleum class A (FP<23 "C). Safety
measures include prohibition of employment of women and young persons, two flame traps to prevent
flash back from burner to the plant, one trap being nearest to the plant, leakproof valves and pipes,
separate well ventilated building for gas generation, proper fire extinguishers for petrol fires, permission
of the CIF to manufacture petrol gas, prevention of spills and leaks, warning notice for no smoking and
not carrying any matches, naked light etc., no entry to unauthorised person to petrol vessel, flameproof
electric fittings, doors opening outside or sliding and repairing of petrol vessel only after steam cleaning
and rendering safe for repair.

For Sch.l3 GFR, Sch.23 MFR and Sch.SI TNFR see foregoing Part 21 on flammable liquids.

IS : Petroleum - glossary 4639, hydrocarbon solvents 1745, coke 1448, 8502, gas containers 4093,
gas measurement 8818, industry - pipe threads 3333, 9996, flanges, fitting and C.I. pipes 3516, bauxite
3605, jelly for cosmetic industry 4887, meters, accuracy requirements 2801, storage tank, maintenance &
operation 9964, fabrication 10987, sampling 1447, test methods 1448, gauging 1518, temperature
measurement 1519, filling machine 3047, measurement instrument 3032, vehicle tank for calibration
2383.

See Part 5 of Chapter 18 for other IS.

26 PETROLEUM REFINERY AND LPG BOTTLING PLANTS

A simple refinery carries out atmospheric and vacuum distillation and produce naphtha and
limited products. Other refineries have more processing units such as cracking, alkylation, reforming,
isomerisation, hydro treating and lubricant processing. A refinery operation includes 7 areas

1. Separation of crude oil.

2. Conversion of hydrocarbon molecules.
3. Treating crude oil fractions.
4. Blending hydrocarbon products.
5. Auxiliary operating facilities.
6. Refinery offsite facilities and
7. Emission and effluent control. .

Detailed safety norms are prescribed by Oil Industry Safety Directorate and known as OISD
norms or standards. They are available in such oil industries.

Some OISD standards are listed below.

OISD Standards :

Sr. No. OISD Code No. Name

1 105 Work permit system
2 106 Process design and operating philosophies on pressure
relief & disposal system.
3 110 Recommend practices on static electricity
4 112 Safe handling of air-hydrocarbon mixtures and
pyrophoric substances
5 113 Classification of area for electrical installations at the
hydrocarbon processing and handling facilities.

Fundamentals of Industrial Safety and Health 23- 42 Safety in Construction Industry

 6 117 Fire protection facilities for petroleum depots and
terminals
7 118 Layouts for oil and gas installations
8 119 Inspection of pumps
9 120 Inspection of compressors
10 121 Inspection of turbines & diesel engines
11 123 Inspection of rotating equipment components
12 124 Predictive maintenance practices
13 125 Inspection and maintenance of mechanical seals
14 126 Specific maintenance practices for rotating equipment
15 127 History recording of rotating equipment
16 128 Inspection of unfired pressure vessels
17 130 Inspection of pipes, valves and fittings
18 131 Inspection of boilers
19 132 Inspection of pressure relieving devices
20 134 Inspection of heat exchangers
21 135 Inspection of loading & unloading hoses for petroleum
products
22 137 Inspection of electrical equipment
23 140 Inspection of jetty pipelines
24 142 Inspection of fire fighting equipment and systems
25 144 LPG bottling plant operations Vol-I Design
philosophies
26 144 LPG bottling plant operations Vol-II Operating
practices
27 144 LPG bottling plant operations Vol – III Inspection &
maintenance practices
28 144 LPG bottling plant operations Vol – IV Safety & fire
protection
29 145 Guidelines on internal safety audits
30 146 Preservation of idle electrical equipment
31 147 Inspection and safe practices during electrical
installation
32 148 Inspection and safe practices during overhauling
electrical equipment
33 149 Design aspects for safety in electrical system
34 152 Safety instrumentation for process system in
hydrocarbon industry
35 153 Maintenance and inspection of safety instrumentation
in hydrocarbon industry
36 154 Safety aspects in functional training
37 155 Personnel protective equipment (part I)
38 155 Personnel protective equipment (part II)
39 156 Fire protection facilities for petroleum depots and
terminals.
40 157 Recommended practices for transportation of bulk
petroleum products
41 160 Protection to fittings mounted on existing LPG tank
trucks
42 161 Rescue and relief operations involving tank truck

Fundamentals of Industrial Safety and Health 23- 43 Safety in Construction Industry

 accident carrying LPG
43 162 Safety in installation and maintenance of LPG
cylinders manifold
44 166 Guidelines for occupational health monitoring in oil
and gas industry
45 169 Small LPG bottling plants – Design and fire protection
facilities.

Safety Measures in Petroleum Refinery _

1. H2S generation should be used to get pure sulphur.

2. Hydrocarbon vapours should be controlled by floating roof tanks, double mechanical seal and
leak detectors.
3. Safety distance should be maintained as per OISD, CCE and TAC norms. Petroleum Act and
Rules should be implemented:
4. Computerized system to prevent overflow, over filling and leakages.
5. Automatic detection and alarm systems for flammable and toxic gases throughout the plant.
6. Deluge water spray system on tanks, pumps, critical vessels, air coolers etc.
7. Aviation lights on all tall structures.
8. Explosion proof control rooms.
9. Use of HAZOP studies from design to operation stage.
10. Zero effluent discharge and minimization of SOx, NOx, CO, H 2S, NH2 and un-burnt carbon
discharges.
11. Efficient dust control measures for dusts of coal, coke, sulphur and other materials.
12. Efficient communication and fire fighting systems throughout the plant.
13. On-sight and off-sight Emergency plans, SOPs, work permits, safety audits, risk assessment and
control measures, safety policy, safety committee, medical examinations of workers, safety
training and use of necessary PPE are all essential.
14. Double staircases/safety ladders should be provided on all tall structures where any worker has to
go for any work.
15. High noise areas should be marked. Noise reduction program should continue. Ear protectors
should be used.
16. All safety devices should be regularly checked and record maintained. The factories Act and
Rules should be strictly followed.
17. Isolation valve below the safety valve should be remotely operated (ROV) for high hazard
chemical like LPG, Propylene, Benzene etc.
18. On rail/road tanker filling gantries, vapour exposure should not come to workers. Their discharge
should be safe. Recovery system should be provided. Interlocking of earthing clamps with loading
arm is safer.
19. Travel distance on platform should not exceed 22.5 mt without exit as per GFR.
20. Doctors should take factory rounds to see actual work places and exposures to workers.
21. Services of Industrial Hygienist should be utilized.
22. In laboratory, contaminated air should not be re-circulated. Fume hood sash height should be such
that face velocity 0.5 m/s is available.

Safety Measures in LPG Plant :

Fundamentals of Industrial Safety and Health 23- 44 Safety in Construction Industry

 An infrastructure of one good LPG Bottling plant is described below.

LPG plant is having fully automated fire fighting facility in the form of sprinkler system and
hydrant network which is spread all over the plant. For fire fighting purpose, water is stored in separate
tanks which last for 4 hrs of fire fighting. For catering water to the sprinkler and hydrant system, fire
engines are provided alongwith jockey pumps which automatically maintains a water pressure of 8
kg/sqcm in the hydrant and sprinkler lines. All the Horton spheres. Pump House and Sheds are provided
with the sprinkler system which automatically operates if the temperature in these areas rise to 79 °C
during an emergency. The operation of sprinkler system will start the fire engines automatically and will
pump water in the sprinkler lines. All the facilities are covered with a well maintained hydrant and
monitor network which is again fully automatic. Besides this, fire extinguishers of DCP and CO, type are
provided near all the facilities as per OISD norms which are checked monthly.

For fire fighting purpose fire organisation chart is prepared which comprises of employees of the
plant itself. The fire organisation is basically divided into three teams viz. (1) Fire Fighting team (2)
Assisting team (3) Rescue team. All the employees working in the plant have been allocated a job to be
carried out during an emergency. For accessing the performance of the teams, Fire Drill is carried out
every month and Disaster Drill is conducted once in a year.

Plant is also equipped with fire fighting accessories like fire entry suit, fire proximity suit, water
gel blankets, different kinds of nozzles, low temperature clothing, breathing apparatus etc.

General safety measures include :

1. Continuous monitoring of hydrogen sulphide gas, carbon monoxide, ethyl merceptan and other
toxic gases.
2. Safe shutdown procedure and start-up procedure should be followed with sequential steps.
3. Good maintenance by blinding or blanking off, electrical lockouts, gas tests and hot work permits.
4. Protective clothing and equipment.
5. Ventilation and air pollution control.
6. Gas monitoring programmes.
7. Leak and fault detection.
8. Control of catalysts hazards.
9. Medical check-ups and industrial hygiene.
10. Fire protection.

IS : Glossary 4639, ventilation in petrochemical plants and refineries 12332, refining industry,
effluent treatment 10044, air pollution in petroleum refineries 10179, limits of gaseous emission 8636,
LPG 4576, LPG storage installations 6044 (Part I & 2), jointing compounds 3465.

Fundamentals of Industrial Safety and Health 23- 45 Safety in Construction Industry

 See IS in foregoing Part 25, Part 5 of Chapter18 and Part 3.1, 3.2 and 3.5 of Chapter 28.

27 PHARMACEUTICAL INDUSTRY

Because of strict requirements of Drugs and Cosmetics Act and Rules, generally pharmaceutical
factories are neat and clean and the plants are properly laid out. Some safety measures include :

1. Safety from chemicals, chemical processes and vessels as described in Chapter-18.

2. Guarding of all machinery, their drives and dangerous parts.
3. Hood and exhaust ventilation for solvent baths and similar processes.
4. Temperature controls for ovens and dryers.
5. Extremely sensitive methods of sampling and analysis.
6. Medical check-ups.
7. Good manufacturing practice i.e. GMP (See Part 2.11 of Chapter-19).

Mostly ovens and driers are used in pharmaceutical or bulk drug industries. Statutory provisions
for them are as under.

Rule 68G, GFR, for Ovens and Driers provides as under :

This rule is applicable to ovens and driers operating at a temperature higher than ambient
temperature and in which flammable/explosive air mixture may be evolved in an enclosed structure. It is
not applicable to those of capacity below 325 litres and used in laboratories or kitchens.

1. Separate Circuit:
Separate electrical power supply with isolation switch should be provided.

2. Design, Construction, Test & Examination :

(1) Proper design on sound engineering practice, good construction, sound material,
adequate strength and free from patent defect.
(2) Testing by a competent person.
(3) Retesting after repair or alteration and certified by a competent person.

3. Safety Ventilation:
(1) Centrifugal fan/s for dilution of air mixture and speedy exhaust.
(2) Safe dilution level is less than 25% of its LEL. 50% of LEL can be allowed if continuous
monitor with alarm at 50% LEL is provided which shuts down heating system at 60% of
LEL.
(3) If above ventilation system is not efficiently working or dilution level is not as mentioned,
oven or drier shall not be operated.
(4) Exhaust of ventilation shall be away from the workroom. It should not re-enter through
windows/doors.
(5) Fresh air should be evenly circulated in oven/drier without any. air pocket.
(6) Throttling damper must allow minimum ventilation rate in its maximum throttling
position.

4. Explosion Panels :
(1) All ovens/driers of more than 0.5 nr" internal space shall have explosion panels (hinged or
fragile doors) to release the pressure of accidental explosion.

Fundamentals of Industrial Safety and Health 23- 46 Safety in Construction Industry

 (2) Size of such panel - 2200 cm2 per Im" volume of the oven/drier.
(3) Should open at roof or walls where no person works.

5. Interlocking arrangements:
(1) Ventilating fans must start first before the feed conveyor starts.
(2) Failure of ventilating fans will automatically stop the feed conveyor, fuel supply,
ignition and the heat source.
(3) Failure of the conveyor will close the fuel valve, ignition and the heat source.

6. Purging by pre-ventilation:
Automatic pre-ventilation system will change 3 times the fresh air volume before starting the
heating and conveyor feeding.

7. Temperature Control:
Automatic temperature control to ensure its safe limit. Multi stage temperatures will be
maintained within the designed limits.

8. Prevention of Dripping:
Dripping of combustible material on heaters or flame shall be prevented.

9. Test, Examination, Ignition & Maintenance :

(1) Trained responsible person will thoroughly examine all parts at frequent intervals.
(2) Register shall be maintained for above work.

10. Trained Operators:

Only an adult (above 18 years) and trained operator will be allowed to work on oven/driers.

IS : Pharmaceutical products, packaging, code of practice 14233, plastic containers 7803, rubber
closures 3692, safe use in contact with - PVC 7288, 10148, 10151, polyethylene 7277, 10141, 10146,
styrene polymers 7961,10142,10149.

28 PLASTICS INDUSTRY

This is a fast growing industry. It has three sectors: (1) polymers and moulding compounds (raw
material) manufacturers, (2) processors and (3) machinery manufacturers.

Polymer (resin) Plants should include :

1. Plant design and layout for fire and explosion control, safe venting, storage etc.
2. Control of exothermic reactions and training of operators.
3. Emergency Plan to control fire, explosion and gassing.
4. Prevention of falls (see Chapter-16).
5. Use of PPE.
6. Splash guards.
7. Exhaust ventilation.

Plastic Processing Industry converts bulk polymers into finished articles and includes :

1. Guarding of press platens of compression, transfer, injection and blow moulding machines.
Effective or double interlocking is essential.
2. Trip device at rollers and calendars with nip guards.

Fundamentals of Industrial Safety and Health 23- 47 Safety in Construction Industry

3. Programmed electronic controls which are more safe.
4. Good housekeeping, cleaning and machinery layout.
5. Static eliminators or earthings to machines where plastic film or sheet travels.
6. Hopper feeders to extruders and granulators. Guards on drives of extruders and insulation of hot
surfaces.
7. Fine plastic powder may cause explosive mixture, therefore it should be controlled in an enclosed
system with relief panels venting at low pressure (@ 0.05 bar) to a safe place.
8. Fire safety from flammable liquids.
9. Separate storage for peroxides to manufacture glass reinforced plastic (GRP).
10. Exhaust ventilation near toxic and acid fumes, isocyanates, formaldehyde resins, styrene vapour
and chloririated hydrocarbons.
11. Safe disposal and burning of plastic waste particularly PTFE and urethanes.
12. Noisy granulators and ultrasonic welding machines should be separated from working area.
Coating the machine with sound deadening material and fitting baffles at the feed opening reduce
noise. Wear hearing protection.

IS : Industry, glossary 2828, fire safety code 11457, Plastic - for food packaging 10172, container
for Vanaspati 10840, 11352, pouches for milk 11805, for edible oils 12724, 12883, 12887, brattice
sheeting, unsupported, fire resistant 11884, button 1461, 1465, .chair 13173, clays for ceramic industry
4589, container for fuel 7394, emulsion paint 4511, films for electrical purposes 11298, laminates 5746,
measuring cylinder, graduated 10073, mechanical properties test 8543, moulded briefcases 9848,
packaging material 10106, packaging terminology 7019, pipes farm drainage 9271, reflectors, lighting
fittings 3287, spectacle frame 3693, suitability for food packaging 10171, Surgery - scissors 4275, 4281,
needle holder 4245, respiratory 4587, dissecting 4282, forceps 9184, Tests 8543, use in instrument
industry 7078, welding, glossary 5687, transparent sheet 9035, 9036, water bottles 8688, wood 423,
adhesive tapes 7809, 13262, valves, float diaphragm type 13049, cartridge for shot guns 12497, strain
ratio V for sheet metals 11999, PVC lining for chemical process vessels 4682, method of testing 13360,
hoses and tubing, bending tests 112656, plasticiser 9591, 3672, 6627, 9572.

29 POLYMER PLANTS

In organic chemistry certain giant molecules such as starch, rubber, plastic .or resin, synthetic
fibres, cellulose, proteins are called polymers and plants manufacturing them are polymer plants. Thus
rubber manufacturing plant, synthetic yarn (nylon, terylene etc.) unit, plastic, resin or silicon making
factory or a starch manufacturing factory can be called a polymer plant.

The polymer (bigger) molecules are built up of smaller units joined together and form a repeating
structure. The repeating structure or the recurring unit in a given molecule is called the monomer, and the
entire molecule composed of several such repeating units is called a polymer. Thus we can say that
rubber is a polymer of isoprene, starch of a-glucose and cellulose of (3-glucose.

Polymerisation process is of three types (1) Addition polymerisation i.e. the combination of
monomers either of the same kind or different kind by a process of addition involving no loss of
fragments, for example, ethylene - polythene. (2) Copolymerisation involves two different types of
monomers, for example, vinyl chloride with vinyl acetate. (3) Condensation polymerisation means the
combination of monomers by a process involving loss of a simple fragment or a molecule of water. The
terminal units of the polymer chain may be different from the units inside. For example, polyester from a
dialcohol and diacid. The alkyd resins are such polymers obtained from phthalic acid and glycol or
glycerol. Linear polymers are thermoplastic and cross-linked polymers are thermosetting.

Fundamentals of Industrial Safety and Health 23- 48 Safety in Construction Industry

 Proteins, starch and cellulosic fibres, plastics and resins are used to make thousands of industrial
products. The variety and names of polymers are many, only a few are mentioned below :

Hazards and Controls :

Mostly the polymerisation processes are carried out in totally enclosed system and therefore the
hazards are reduced to much extent. Machinery is also mostly enclosed. The hazards are possible from
exposure to raw materials, leakage and spillage, dusts and fumes, hot surfaces and radiant heat, noise and
vibration and heat and humidity.

Chemicals like formaldehyde andcaprolactam cause burning in eyes, nose and throat. High
temperature and pressure of thermic fluid (e.g. Dowtherm) in oil heating system may cause burn and
sometimes fire. Extrusion machines have hot surfaces which need insulation to prevent burn injury and
hopper feeder to prevent hand contact with screw conveyor inside. Cutting machines for plastic, rubber
and other hard substances need safety guard on cutting blade and machine drives. Charging of toxic
materials (powder or liquid) need enclosed system with local and room exhaust fans and necessary
respirators.

Polyamides used to manufacture epoxy resin are skin irritant. Acrylonitrile used in
polyacrylonitrile (PAC or acrylic) fibre is toxic, skin irritant and carcinogenic. This effect was noticed in
polymerisation workers. Another chemical dimethyl formamide (DMF) causes digestive effects,
abdominal pain, skin effect and pancreatitis to workers exposed to it. (e.g. spinning bath and solvent
tanks).

Styrene monomer, acetone (used in cleaning) and organic peroxide catalysts used in making
polyester resins may cause fire and explosion. Styrene vapour may cause narcosis (effects on head, nose
and throat).

To control such vapour, dilution ventilation and spray booth are necessary. TLV is more critical
than the LEL of styrene. (Styrene monomer-phenylethylene or vinylbenzol – C 8H8 TLV 50 ppm or 215
mg/ m3 STEL 100 ppm or 425 mg/m3, LEL 1.1%, UEL 6.1%, FP-33 °C, VD 3.6, poison via oral, ivn).
The inhalation dose of styrene can be measured by analysis of exhaled air (gas chromatography).

Solvent storage should be kept away, covered metal containers should be used to collect solvent
wastes, electric fitting should be flameproof and smoking must be prohibited. Direct contact of peroxide
catalysts should be avoided. Neoprene or plastic gloves are not affected by solvents.

Itching from fibrous glass particles can be minimised by good housekeeping, ventilation, use of
long sleeves, barrier creams and frequent washing with soap and water.

Ethylene, propylene and other olefin members to make polyolefins (polymer) are weak
anaesthetics at a concentration above 60%. Freezing burns due to liquid propylene and hyperplasia due to
prolonged exposure to diolefins have been reported. Aluminium alkyls are flammable in air and explosive
in water, their fumes may cause lung damage and in solution it causes burns. Adequate body PPE should
be given to workers.

Ethylene, propylene and butylene are gases at room temperature, highly flammable or explosive
when mixed with air or oxygen and large fires of olefins are difficult to extinguish. In case of fire, their
supply should be stopped, fire should be allowed to burn out and adjacent structures be cooled by water.
Small fires may be controlled with CO2 or DCP extinguishers.

Fundamentals of Industrial Safety and Health 23- 49 Safety in Construction Industry

 Polystyrene is made by polymerisation of styrene and other monomers. They are flammable.
Polymerisation process is highly exothermic and uncontrolled reaction may reach explosive stage.
Cooling and pressure relief devices on vessels are essential. Foamed polystyrene is also flammable. Most
of the chemicals are toxic. Therefore leakage should be prevented by quick maintenance and enclosed
system. Female workers exposed to polystyrene production showed disturbed menstrual cycles, sexual
activity, disturbed pregnancy and child birth. Biological indicators are blood styrene level and styrene
metabolites in urine. Polystyrene dust may cause weight loss and erythrocyte, leucocyte or hepatic
changes.

Polystyrene process should be fully enclosed, automated or remote-controlled. Manual handling

should be replaced by mechanical one, leakage should be stopped, local exhaust ventilation on air
contamination, respiratory and other PPE to the workers and their medical examinations are necessary.

In making various types of synthetic rubbers, solvents like hexane, styrene, butadiene,
chloroprene, acrylonitrile, toluene diisocyanate (TDI) and other isocyanates in making elastomers,
ethylene dichloride (EDC), methyl chloride, ethylene, propylene etc. are used. Safety measures are
required depending on properties of these dangerous chemicals, their splashes and leakage, pressure
release, machine parts, entry into vessels, cuts and burns, fall from height and on the floor.

Health hazards are possible in handling raw rubber containing extender oil and carbon black.
During fire CO hazard is also possible.

Workers should be made aware of all these hazards and properly trained. Gas detectors with
alarms, welding permit, vessel entry permit, exposure measurement, good ventilation, rubber gloves, eye
protection, hearing protection and washing facilities are also required.

Thus depending on a type of polymer plant, a variety of control measures are applicable.

IS : Styrene polymers, safe use in contact with foods etc., 7961, 10142,10149, styrene vinyl
benzene 4105, styrenated phenol 7351, styrene butadiene rubber (SBR) - latex 11356, latices, tests 4511
(Part I to 6), tests 4518 (Part I & 2), Polystyrene - for insulation 4671, wall tiles 3463, fixing 4112, sheets
5210, Polybutadiene rubber (PBR), test methods 10016, Polyester resin bath tubs 6411, tank, chemical
resistant 10661, Polyolefin - plastic container 7408, fibre analysis 9896, Polypropylene and its
copolymers, safe use with food stuffs, drinking water etc., 10909, 10910, thermoplastics 10951,
Polyurethane foam - domestic mattresses 7933, insulation, code of practice 13205. PVC - resin 4669,
sheeting, flexible 2076, boots, oil & fat resistant 13038.

30 POTTERY INDUSTRY

This is one of the oldest human crafts and many techniques have been changed during centuries.
The basic processes of modern industry are preparation of body ingredients, forming and shaping, biscuit
firing, glazing, glost firing and decoration. The product is classified as tableware, sanitary tiles and
industrial ceramics. The safety measures include :

1. Interlocked guards, mechanical feeding and takeoff at machines.

2. Good house-keeping.
3. Mechanical handling.
4. Control of gas hazards at kilns and dryers.
5. Dust (free silica) control by substitution by dustless process or reducing free silica, isolation from
the work room with exhaust ventilation and by using dust mask.

Fundamentals of Industrial Safety and Health 23- 50 Safety in Construction Industry

6. Processes of calcining, crushing and mill feeding in a closed system under negative internal
pressure to extract dust.
7. Other processes including glazing under hood and exhaust ventilation.
8. Vacuum cleaning and washing of floors and tables.
9. Efficient dust filtration plant not allowing re entry of the filtered air.
10. Dust monitoring and control.
11. Medical examination including X-ray test.
12. Avoidance of lead or restricting to 5% soluble lead in glaze process with exhaust ventilation. Lead
in glaze is toxic.
13. Use abrasive rubbers and grinding heads instead of chemicals for cleaning unwanted decoration.
14. Temperature control near kilns and glaze dryers.

Statutory Provisions :

Provisions of Schedule 25 Rule 102, GFR and Sch.lS, Rule 95, TNFR are summarised as under :

1. Applicability:

This schedule applies to all factories engaged in manufacture of pottery except where following
articles are made –
(1) Unglazed or salt glazed bricks and tiles.
(2) Architectural terra-cotta made from plastic clay and either unglazed or glazed with a
leadless glaze only.

2. Definitions:

The words pottery, leadless glaze, low solubility glaze, fettling, efficient exhaust draught, potter's
shop etc. are defined.

3. Efficient Exhaust Draught :

Many processes have been mentioned which cannot be carried out without efficient exhaust
draught. These include manipulation of dry and unfritted lead compound, fettling operations, shifting of
clay dust, pressing of tiles from clay dust, loading and unloading of saggars, brushing, crushing, dry
grinding, cleaning, lifting of materials, weighing, mould making etc. unless the machine is so enclosed or
material so damp that no dust can be given off.

4. Other Measures Prescribed

(1) Processes giving dust or using dry lead compound should be separated. Women or
young persons cannot be employed in such processes.
(2) Use of leadless glaze or low solubility glaze is permitted and that of high lead content is
prohibited.
(3) Potter's wheel (Jolly and Jigger) should have screen to prevent clay scrapings being
thrown off.
(4) Damp saw dust or other moist method should be used to prevent flying dust during
cleaning of floors.
(5) PPE like overalls, head-coverings, aprons and dust respirator should be given as per need.
(6) One water tap or stand pipe for every five workers with their spacing 1.2 mt or more and
towels, soap and nail brushes should be provided. Washing time shall be allowed before
each meal and at the end of the shift.

Fundamentals of Industrial Safety and Health 23- 51 Safety in Construction Industry

 (7) Mess room of size 0.93 m' per person and will facilities of washing, drinking water,
warming food and furniture. The room should be clean. well ventilated and in charge of a
responsible person;.
(8) Food, drink, pan supari, tobacco etc. should not be consumed in the work room.
(9) Cloak room to put personal clothing and separate arrangements to put PPE.
(10) Medical examination by the certifying surgeon within 7 days from the first employment
and thereafter at every 3 months of workers engaged with dry and unfritted lead
compound and at one year of workers engaged in dusty processes. Fitness certificate in
form No. 27-A shall be granted by the Certified Surgeon. Record in health register. Unfit
person can be re-employed after fitness certificate by the certified surgeon.

IS : Clay - ball for ceramic industry 4589, bricks 6165, 5454, 3495, burnt 7556, Hollow bricks for
walls and partitions 3952, filler blocks for floor and roof 6061, pipe products glossary 2248, Tiles 3951,
3367, roofing tiles, half round flat 13317, china clay 2840.

Ceramic tiles - 13711, 13712, 13753 to 13756, Tests 7571, 13630, Tower packing 7087, water
filter 7402, components for thermocouples and thermometers 8495, Limits of toxic materials 9806,12038.

Ceramic grinding media and lining 7775, Earthenware & dinnerware 2857, 3149, bone china
crockeryware 6958, Glossary for - ceramicware 2781, enamelware 2717, stoneware 2839, stoneware,
crockeryware 11745, stoneware coatings 2838, colour test for vitreous enamel coatings 8709, methods of
test for vitreous enamels and frits 8687 (Part I & 2), 3972 (Part I, Part 2, Sec. I to II), plaster of Paris for
ceramic industry 2333, plastic clays for ceramic industry 4589, porcelain crockeryware 3505, powdered
talc for ceramic industry 10429, pyrophyllite for ceramic industry 11477, quartz for ceramic industry
11464.

31 RUBBER INDUSTRY

The rubber may be natural from rubber tree or synthetic classified as homopolymers and
copolymers. Safety measures include :

1. Interlock guard on the knife of bale cutting machine.

2. Trip guard or sensitive safety bar on horizontal double roll mills for mastication and compound
mixing process.
3. Interlocked guard to prevent access to the trapping area near feed hopper of internal mixing
machine.
4. Distance guard and feed hopper to an extruder machine. Its fumes should be removed away by
exhaust ventilation. Hot surface insulation.
5. Manger type distance guard at the feed nip of calendar machine and fixed guard or electrically
interlocked guards on other nips.
6. Interlocked lid of agitator.
7. Solvent vapour removal on spreading machine. Exhaust ventilation, flameproof electric
equipment, use of non ferrous tools and antistatic footwear and earthing of machinery are
necessary.
8. Guarding of punching, stamping, cutting and slitting machines.
9. Follow Rule 61, GFR for vulcanisers (curing pans or autoclaves). Its lid should be interlocked.
Safety valve, pressure gauge, PRV etc. should work efficiently.
10. Interlocked guard on a moulding press. Photo cell guard on a large press. Trip bar at a safe
distance.
11. Good ventilation and cool wall colours in moulding plant to reduce heat effect.

Fundamentals of Industrial Safety and Health 23- 52 Safety in Construction Industry

12. Exhaust ventilation on buffing.
13. Power press guarding.
14. Guarding of Latex rubber machinery and use of PPE.
15. Exhaust ventilation for nitrous fumes.

Synthetic rubber manufacturing should include :

1. Fire prevention for flammable materials. Well trained fire fighters. Gas detectors with alarms.
2. Handling precaution of pyrophoric catalysts.
3. Handling of volatile monomers and solvents in closed system. Good general ventilation.
4. Self-breathing apparatus to handle large leaks and spills of toxic material.
5. Steam purging of vessel to remove chemical vapours.
6. Personal protective equipment.
7. Washing facilities.
8. Noise control.

Statutory Provisions:

For an abstract of Schedule 4, Rule 54, GFR see Part 4.4 of Chapter-14.

IS : Rubber - industry glossary 7503, acrylonitrile butadiene 8683, aprons for hospital 6407,
belting - transmission 1370, conveyor 1891, 14206, Boot 13695, 13995, 5557, knee boots 3738, bottle'
for hot water 1867, Compounds - sampling and tests 7086, vulcanised 5192, Hose, wire reinforced 7651,
Flooring materials 809, floors code for laying 1197, Footwear - sampling 6368, use at low temperature
14290, antistatic 13575, 13996, Rubber for dairy industry 6450, gasket 11149, for pressure cooker 7466,
Gloves for electrical purposes 4770, post mortem 4149, surgical 4148, hawai chappal 10702, seals 13249.

Rubber hose - agricultural spray 1677, air hose 446, hot water 5821, fire fighting 636, chemicals
7654, petroleum tankers 10733, fuel dispensing 2396, hydraulic 10660, oil and solvent resistant 635,
water - general purpose 444, sampling and test 443, sand blasting 5894, 6417, steam 10665, suction for
fire services 2410, water suction - light duty 2482, 8189, heavy duty 3549.

Methods of test for natural rubber 3660 (Part I to 54).

Rubber - ice bags 3867, insulated cable, current rating 3961, jointing 638, latex 5430, 11001,
foam products 1741, lining for chemical equipment 4682, mat for electrical purposes 5424, gaskets foe
joints with CI pipes 12820.

Rubber packaging - 5190, styrene - butadiene 11356, symbols 6611, tests 3708, 9316.

Natural- raw 4588, 5599, tests 3660, formula for evaluation 7499, latex based 9827.

Rubber - reclaimed 7490, tests 6306, rollers for offset printing 11610, sheetings, hospital 4135,
synthetic, test methods 11720, tests for feeding bottles 3565, tul)es, cycle 2415, Ttfcing for - LPG 10908,
general purpose 637, medical use 5680.

Rubber vulcanised - chemical analysis and tests 3400, storage 6713.

Rubber based adhesives for - tubes and tyres 2560 to 2562, PVC tiles 12830.

Rubberised - coil cushioning 11060, coir sheets 8391, fumigation sheets and covers 4810.

Fundamentals of Industrial Safety and Health 23- 53 Safety in Construction Industry

 See also IS in foregoing Part 29.

32 SHIP BUILDING, REPAIRING AND BREAKING

Ship building and breaking at shipyard or dock, engage many workers and attract provisions of
the Factories Act and Rules, though the Dock Workers (Safety, Health and Welfare) Act 1986 (and
Rules) is a specific legislation on the subject. See Part 8 of Chapter-28 for Dock Safety Laws.

In addition to the bad weather conditions and climatic effects, the working conditions are also
very risky as it involve handling of large sized heavy steel plates, pipes and other articles, fabrication,
machining, erection, welding, cutting and work in confined spaces as well as at heights. Welding and
cutting in oil tanks have caused many fatal accidents. Raising and lowering of heavy parts and materials
and mechanical lifting cause hazards. Falls from different levels, striking against objects, stepping on
objects, struck by falling bodies, injuries by hand and power tools, lifting gear, fire, explosion and
gassing, burns by hot surfaces, effects of noise and vibration, fumes and eye burning from organic
pigments, resin and solvents, loose or temporary wiring, inadequate lighting, dusts from asbestos
insulation and shot blasting are also possible. Most of the workers are employed through contractors
where training and supervision are poor.

Occupational diseases specific to this industry are : arc eye due to welding, deafness due to high
noise, white finger due to vibrating tools, lung irritation, narcosis from exposure to solvent fumes,
asbestosis, mesothelioma, carcinoma, asthma, siderosis a banign lung condition due to inhalation of iron
oxide dust or flue from welding or burning, dermatitis or skin rashes and cataracts due to ionising
radiation and lasers.

Statutory Provisions:

Rule 68H, GFR gives statutory provisions. Its summary is given below :

1. Applicability:
This rule is applicable to "operations" of construction, reconstruction, breaking, repairing,
refitting, painting and finishing of ship or vessel.

2. Definitions:
The terms certificate of entry, hot work, naked light certificate, oil, oil tank, tanker, shipyard,
stage and staging have been defined. Oil means any liquid having FP below 132 °C and also
includes lubricating oils, liquid methane, butane and propane.
Certificate of entry and naked light certificate are issued by a competent analyst after
testing the atmosphere in oil tank to allow a person to work.

3 Ladders:
Ship's accommodation ladders or sound gangways (width more than 55 cm. with each side railing
of 90 cm.) of adequate strength and securely fixed should be provided. Rope ladders and
boatswain's chairs, ropes, gears etc. should be of sound material and securely attached.

4. Throwing Down Materials and Loose Articles: .

Materials or articles shall not be thrown from a height but shall be properly lowered. When this is
not possible, warning notice shall be displayed or work shall be done under direct supervision of
an authorised person. Materials left, lying anywhere and likely to fall should be safely collected.

Fundamentals of Industrial Safety and Health 23- 54 Safety in Construction Industry

5. Entry into Confined Space :
A space likely to contain dangerous fumes shall not be certified for human entry unless it is
properly purged, ingress of dangerous fumes is prevented, sludge or other deposit liable to give
off dangerous fumes has been ventilated and tested for adequate air (oxygen) for respiration. If
oxygen is insufficient, breathing apparatus and safety belt shall be utilised.

6. Welding, Cutting and Heating :

1. Pipes containing oxygen or flammable gas/vapour shall be safe and properly maintained.
They should be securely attached by means of suitable clips.
2. Pressure reducing valves shall be provided.
3. Back pressure valve and flame arrester shall be provided in the acetylene supply pipe.
4. Valves should not open accidentally. They should be securely closed when not in use.
5. Gas pipes, not in use, shall be kept at the top, safe and ventilated places and may be dis-
connected from source if possible.

7. Naked light and Hot work on Oil carrying Vessels:

Normally no naked light, fire or lamp (not being safety lamp) or hot work shall be permitted
unless a naked light certificate is obtained and is in force or such work may not produce sufficient
heat to ignite flammable material.

8. Cleaning of Oil-tanks:
Before a test for flammable vapour is carried out with a view to issue a naked light certificate, the
tank shall be cleaned and ventilated. First volatile oil shall be vaporised, then residual
sludge/deposit shall be removed and thoroughly ventilated by mechanical or effective means to
remove all oil vapour.

9. Personal Protective Equipment:

Hand protection, goggles, helmets, face shields, screens, safety belts etc. shall be provided to
workers as per requirement.

10. Others:
1. No young person shall be employed to clean, break , cut or spray asbestos.
2. An experienced supervisor shall be employed in a shipyard for exclusive observance of
these rules.

IS : Safety and health requirements in electric and gas welding and cutting operations 818, ship
geometry glossary 8214, ship building, noise level on board 13161, desk machinery 8650, 12719,

Ships - ventilation and pipeline systems 3733, 9423, 9752, window glossary 11914, ordinary
8886, safety glossary 6640, window positioning 12693, window gaskets 8809, air pipe hood 6636, AC
requirements 8434, 9114, binnacles - 5289, 4045, cabin ventilator 3941, derricks, 4478, 5521, direction
finder 4259, dog-step ladder 8450, doors 4384, electrical installation 10242, eye plates 6203, 6225, fire
appliances 3947, flag staff 7723, conventional signs 6737, hydrodynamic terms, glossary 8214, 5314,
marine engines, boilers and steel castings 2986, mechanical ventilation 5858, piping system 4693, 7304,
propellers 8215, 9126, scupper 5875, 5876, signalling whistle 11608, steel - ladder 6176, structure 2985,
wire reel for inland vessels 4659. .

Shipboard - AC system 8649, 9734, indicator lights 9421, lamps 2592, mechanical ventilation
4881, cables 10242.

Fundamentals of Industrial Safety and Health 23- 55 Safety in Construction Industry

 Ship building - Arc welding 5525, carbon steel forging 3261, cargo gear book 7248, code of
practice 13930, vibration 13121, 13633, dimensions guidelines 8712, deck insulation materials 14307,
14336, marine radar reflectors 13708, foam material 14317, distress signals 14270, engine fuel oil piping
system 14140, steam traps, guidelines for selection 12794.

Ships - international shore connections 12266, hull, steel plate 5488, structural steel 3039, tools
and outfits guidelines 11160, vibration guidelines 13121.

33 SILK INDUSTRY

Silk is a lustrous, tough, elastic fibre produced by the larvae of silk worms and includes the thread
of cloth made from it Similar synthetic fibre is known as artificial silk. In industrial use the hazards are
similar to those in' the textile industry (see Chapter-21). Shuttle and other guards for looms and good
lighting for spinning and weaving are necessary.

IS : Silk - cloth 1687, coating 3356,

3359, evenness 2944, fabric 3357, 3358, 3561,
handloom 1583, 1686, khadi - national flag of
India 300, Raw test - cleanness 2945, neatness
2946, cohesion 2948, size or count 2942, 2943,
grading 2938, serigraphtest 2947, conditioned
mass 2940, winding test 2941.

Silk - ribbon tap 10056, sarees 2207,

sewing thread for parachutes 3254, webbing
7776, screen printing inks 12530, raw - grading
methods 461.

34 SOAP INDUSTRY

Soap is prepared from triglycerides (animal or vegetable oils and fats) by alkaline hydrolysis
(saponification). It is a water soluble salt of carboxylic acid and is extensively used for cleaning, washing
and textile processing. Safety measures include :

1. Guarding of stamping tools and other machinery. Interlocks and limit switches should be
regularly checked.
2. Follow Rule 61, GFR for steam pressure vessels, blow off valve should be used carefully.
3. Prevention of falls by non-slip floor, regular cleaning and good housekeeping.
4. Safe handling of materials and stacking.
5. Rubber gloves, aprons, boots and goggles or face shields to prevent burns from sodium hydroxide,
sodium silicate, cresylic acid, inorganic builders (alkali phosphates, silicates, carbonates etc.) and
organic builders (starch, cellulose ethers and esters).
6. Lagging of hot pipes and colour coding.
7. Good washing facilities, barrier creams and medical check-ups for dermatitis due to oils or rosin.
8. Temperature near boiling pan should be reduced by vessel lagging, exhaust ventilation and proper
roof height. Fencing of vessel and safe platforms are necessary.

IS : Soap - toilet 284, transparent 839, soap stock 12031. -

Fundamentals of Industrial Safety and Health 23- 56 Safety in Construction Industry

35 SOLVENT EXTRACTION PLANT

Industrial solvents are generally organic liquids like benzene, hexane, xylene, CS,, petrol etc.
They dissolve many substances which may or may not be dissolved in water a fundamental solvent.

Solvents are classified in 9 groups :

1 Hydrocarbons (aliphatic & aromatic) 6 Glycol derivatives

2 Halogenated hydrocarbons 7 Esters
3 Aldehyde and Ketals 8 Ketones
4 Alochol 9 Miscellaneous
5 Ethers

Uses of solvents are many, such as surface coatings, paints & thinners, synthetic fibres, to make
the material soft (plastic) for moulding, extrusion or shaping, to extract oil, fats and medicinal material
from seeds, nuts and bones, degreasing, dry-cleaning and for dissolving chemical reagents. It is used
directly as raw material in organic synthesis also.

Fire, explosion and toxicity are its main hazards. Less harmful solvent should be selected as far as
possible. Local exhaust ventilation to keep the material below its LEL, dyke walls to tanks, flame arrester
and cooling system, flameproof electric fitting and equipment, air as well as biological monitoring,
alarms and trips, respirators and other PPE, and work permit to work in confined spaces are necessary
safety measures.

Statutory Provisions:

Summary of Schedule 21, Rule 102, GFR, Sch.21, Rule 114, MFR and Sch.23, Rule 95, TNFR is
given below:

1. Definitions:
Solvent ex traction plan t means a plant where process of extracting oils and fats from vegetable
and animal sources by use of solvents is carried on. Solvent is a flammable liquid such as Pentane,
Hexane, Heptane used for the recovery of vegetable oils.

Competent person is specially defined for this Schedule. He should be (i) B.E. (Mech.) or
B.Tech. with special knowledge of oil and fat with 5 years experience or (ii) a member of

Fundamentals of Industrial Safety and Health 23- 57 Safety in Construction Industry

 Institution of Engineers (India) with 10 years experience or (iii) of qualification accepted by the
State Government.

2. Location and Layout:

The plant should be 30 metres away from the nearest locality, 1.5 mt. fencing at a distance of 15
mt. from the plant. Boiler house etc. at a distance of 30 mt. from the plant. If godowns and
preparatory processes are within 30 mts. from the plant, barrier wall of non-combustible material
and 1.5 mt. height should be at a distance of 15 mt. from the plant. Prohibition to carry match box
and open flame inside. Smoking prohibited within 15 mt. from the Plant.

3. Electrical Installations:
They should be of flameproof construction. Metal containers of solvent and non energized
electrical equipment to be properly bonded and earthed.

4. Precautions against friction:

Tools, ladders, chains, lifting tackle and footwear to be of non sparking type. Static charge
eliminator on belt drive. Clothing of nylon or other fibre capable of causing static charge are not
allowed.

5. Fire fighting:

Adequate number of portable extinguishers and automatic water sprinklers or open-head deluge
system over the plant are required.

6. Ventilation:
Plant building should have mechanical ventilation providing at least 6 air changes per hour.

7. Venting:
Solvent tanks should have emergency vent to relieve excess pressure in case of fire. Such vents
should open at least 6 mts. above the ground so that vapour should not re-enter the plant.

8. Others:
1. Automatic device to cut off steam and to supply cooling water from overhead tank by
gravity in case of power failure.
2. Magnetic separators on oil cake feeder to remove iron pieces.
3. Flash evaporator to remove solvent from process waste water located 8 mts away" from
the fence but within fenced area.
4. Solvents should not be stored in the plant building. Space of 15 mts within the plant shall
be kept free from combustible material. Spillage shall be cleaned immediately. Daily
removal of oily rags and wastes etc.
5. Trained operators certified by the competent person.
6. Women and young persons prohibited.
7. Vapour monitoring by a combustible gas detector. Sampling locations to be approved by
the CIF. Register is required for record.
8. Examination by the competent person every year. Repairs under the direct supervision of
the competent person.
9. Purging (with inert gas or steam) required before opening for cleaning or repairs or
introducing solvent after repairs.

IS : Solvent - for paints, sampling and test 82, insulating varnishes 10026, petroleum hydrocarbon
1745.

Fundamentals of Industrial Safety and Health 23- 58 Safety in Construction Industry

 Solvent extracted - coconut oilcake 3591, cottonseed oilcake 3592, ricebran 3593.

Test for corrosivity of solvent 13643.

See also Part 5 of Chapter-18 and foregoing Part 20 and 21 of this Chapter.

36 SUGAR INDUSTRY

The growth of sugar factories is very wide and mostly in co-operative sector. Except some small
Khandsari units, generally the sugar mills are large factories running with heavy machinery and big-sized
vessels, employing more than 1000 workers and occupying a bigger area for the mill plant, sugar cane
transport vehicles, sugar godowns, bagasse (crushed fibrous waste) stocks and long conveyor belts,
molasses tanks, solvent extraction plant if provided, residential facilities for mill workers and offices for
other related activities.

The nature of sugar mill machinery pose mostly the mechanical hazards like crush injuries, falls
or slipping from heights, falling into pit or hot sugar juice, hurt by falling bodies or sugar bags, fumes and
gases (SO , HCI, CO, CO,), steam at many places, sugar cane dust (may cause bagassosis), noise and
vibration due to centrifuge machines and vibrating screens, packing machines and large size crushing
gears.

In the process, sugar canes are put on feed (rolling) carrier, pushed ahead by steel beaters and
crushed in two to three sets of heavy rollers. The initial juice contains bagass fibres, clay, grit, albumen,
pectin etc. Bagass fibres cause lung disease known as Bagassosis. The juice is then heated and chemical
agents are added to remove impurities and to get saccharose. After clarification (through heating) the
juice is concentrated in vacuum evaporators till it precipitates in the form of greyish crystals. The
concentrated juice (molasses) contains 45% water. By centrifuging the water is separated and brownish
granulated sugar (brown sugar) is filtered. White sugar is made by refining (Sulpher) process. The filtered
syrup is evaporated in quadruple effect evaporators, vacuum pans and crystallisers till it crystallises.
Centrifugation is again applied to get white crystalline sugar. Vibrating screens are used to separate sugar
crystals in different sizes (grades). It is then weighed, begged and sent to the sugar godowns.

The safety measures include -

I Cane Milling Plant :

Fundamentals of Industrial Safety and Health 23- 59 Safety in Construction Industry

1. Cane handling platform with gantry and gantry columns (not more than 10 m. apart) attendance
platform, approach staircase, sling bar and grab attachment, mechanical/ electrical controls from
crane operator's cabin.
2. Fixed sound guards on motor and gear drives of feeder tables, steel structure to withstand heavy
shocks, inclined tail end to feed into the main carrier.
3. Cane carrier (1800 mm wide), 3 strands chain (150 mm pitch) and sprockets with heavy guards,
hood 'to cover cane knives with inspection door and head-shaft and gears with guards.
4. The cane carrier motors be interlocked with the cane leveller and cutter motors so that the cane
carrier stops when either of these motors trips.
5. Cane feeding chute from cane carrier to the crusher at an angle of 50° from the horizontal. The
chute length should be more than 3.5 m.
6. Guards on gear and motor drives of cane kicker - a rotating shaft (dia > 125 mm) mounted with
more than 20 blades or arms.
7. Totally enclosed reinforced steel hood with suitable swing flaps and bolted top covers on cane
leveller with more than 42 knives and cane cutter with more than 52 knives. The knives should be
of specially shock resisting steel with carbide tips or stellited cutting edges. Guard on flywheel of
the shaft.
8. Crushing mills may be of following types :
Based on sugar cane crushing capacity per day-
For 2500 tonnes-12 rollers-4 steam turbines
For 3500 tonnes-18 rollers-6 steam turbines
Fixed guards on mill gearing, flexible couplings and mill rollers (max. speed 18 mt/min).
9. The juice gutter under the mills shall be made of brass or copper lined MS plates or aluminium
plates of sufficient strength.
10. Cylindrical whirler type pumps of 75 m3/h at 10 m head, non corrosive, non choking type, and
with bronze impellers.
11. Vertical guard or fencing on bagass elevator and conveyor and also surrounding floor or feed
opening and horizontal guards or grills on moving slats and bagass scrappers.
A gangway of open flooring with hand railing alongside the whole length of the conveyor
with access ladders at different platforms including boiler control platform.
12. Testing and maintenance of all cranes and lifting machinery as per Rule 60 of the GFR.

II Clarification Plant:

1. Juice heaters with necessary valves, venting and condensate extraction device with collection
tanks and safety for steam use. Solid drawn brass tubes for heaters with 42 mm ID, 45 mm OD
and total length of tubes not exceeding 4.5 mt
2. Continuous juice sulphitation unit, with lime milk proportioning arrangement, guards on lime
slacker motors, couplings and gear drives and stirres drives. SO 2 absorption tower with safe vent,
effective stirrer, sulphur furnace with cooling water jacket for vertical gas pipes and scrubbers
made of cast iron.
3. Clarifier with flash tank, juice overflow box, scrapper drive, mud overflow box, liquidating pump
etc.
4. Vacuum rotary mud filter with bagacillo sifter, recirculation pump, juice trough, filtrate pumps
and receivers, mud conveyor belt, juice separator, air blower, cyclone separator for vacuum
filters, cake washing hot water pumps and guards for pump couplings and motor drives.

III Evaporation and Boiling Plant :

Fundamentals of Industrial Safety and Health 23- 60 Safety in Construction Industry

1. A quadruple effect evaporator with four bodies (vertical tanks) with two syrup extraction pumps
(one standby), safety valve in the vapour space to open at 0.2 kg/ m2, pressure and vacuum
(compound) gauges, thermometers, condensate extraction pumps, grit catchers, vapour space
height more than twice the calandria height, calandria (bottom heating zone) height not exceeding
2 mt, domes and fittings of suitable save-all design, the calandria tubes should be solid drawn
with 42 mm ID, 45 mm OD, tubes spacing more than 10 mm. and vapour condenser at the end.
2. Syrup and molasses tanks (13 to 15 tanks), bund or dyke, heating coil to molasses tanks, wash out
connection to each tank, wash out gutter with suitable valves, working platform with handrails
and approach stairs along the storage tanks. One molasses dilution tank with stirrer, water and
steam connection is also necessary.
3. Vacuum pans, condensers and injection water pumps requirement is as under :

For plant of Vacuum pans Condensers Water pumps

2500 T 5 6 6
3500 T 7 8 8

Vacuum pans are calandria of low head rapid boiling type with steam tubes (brass), compound
gauges, thermometers, various pipelines and fittings, connections with crystallisers and multi-jet
condensers, heavy molasses and hot water connection through nonreturn valves, guards on stirrer drives
and gears, the injection water pumps - centrifugal and directly coupled, are all necessary.

IV Cooling, Curing and Grading Plant :

Heavy U-type air cooled and water cooled crystallisers are required with stirring arrangement,
guards on stirrer and gear drives and centrifugal machines (15 for 2500 T plant and 20 for 3500 T plant).
Superheated wash water or steam connection, timer controlled automatic brakes, solenoid and pneuma,tic
valves, ploughing speed not exceeding 60 rpm, connection with magma mixtures, guards on magma
mixture drives, guards on pug mill drives, reduction gears and air-compressor drives, steam connections
with NRV for magma and molasses lines, sugar melter, grass hoppers and conveyors, hot and cold air
blowing, sugar elevators and graders (vibrators) with dust catching arrangement, sugar weighing
machines, bag stitching machines, molasses weighing scale and final molasses storage tank (3 to 4) each
of 4000 m" capacity as per IS specification.

Other plants viz. Boiler and steam generating plant. Power generating plant and Miscellaneous
e.g. reducing valves, pipelines, supporting structure, service tanks, water pumps etc. also need due
consideration.

Dust, fume and gas extractors, noise and vibration dampers and medical examination of workers
are also required.

IS : Sugar laboratories 1679, 5527, godown construction 4772, vacuum pan grading 498, filter cloth
1178, inter-carrier chains 9069, sprockets 12198, effluent treatment 4903, crusher 1973, 6983, 6997, juice
hygienic code for sale 8124, stripper 7789.

Sugar confectionery- hard boiled 1008, sampling and analysis 6287, cube 1168.

37 TOBACCO INDUSTRY

Fundamentals of Industrial Safety and Health 23- 61 Safety in Construction Industry

 Tobacco is manufactured into biddies, cigars, pipe, chewing tobacco or snuff. Some factories are
large and fully mechanised but many are small factories employing mostly female workers. Safety
measures include

1. Guarding of all machinery moving parts, drives, shafting, gearing and cutting knives.
2. Nip guards to conveyors and rollers.
3. Prevention of explosion due to tobacco dust.
4. Local exhaust ventilation to dust sources (respirable tobacco dust is 0.3 to 3.6 mg/m").
5. Good housekeeping and vacuum cleaning.
6. Good sanitary and washing facilities, personal, hygiene, protective clothing, dust masks and
medical supervision.

IS : Tobacco - glossary 10335, analytical test 7753, chewing (zarda) flake 2344, minced 3041,
moisture determination 9379, packaging code 10106, packing seaworthy 4698, paste hookah 14332,
sampling 8600, Virginia seedcake 10670.

Tobacco seeds - 3380, grading 8443, oil 5614, test 5643.

38 WOODWORKING INDUSTRY

Woodworking industry includes wood cutting in sawmills, wood preservation and treatment and
making of panels (veneer plywood, chipboard, hardboard), furniture and other products by using
woodworking machines and tools which are mostly dangerous and need strict guarding. The safety
measures include :

Fundamentals of Industrial Safety and Health 23- 62 Safety in Construction Industry

1. Circular saw guarded with adjustable riving knife, guard hood with vertical and horizontal
adjustment, under-table cutter guard and drive guard, readily replaceable blade aperture insert to
prevent the entry of waste, intermediate guide or rip guide to prevent jamming, push stick with
handle and stop/start switches within reach.
2. Guarding of chain saws and hand saws (vertical or horizontal) including blade wheel (drive and
return wheel) guarding, blade guarding, adjustment and maintenance, sawdust exhaust ventilation
and collector, effective brakes within reach and guarding of drives and other dangerous parts.
3. Guarding of surface planner, other planning machines and vertical spindle moulders and routers
with effective and adjustable tool guards with exhaust ventilation with close hood to collect saw
dust and shavings.
4. Tools well sharpened and balanced and vibration damping base to minimise noise.
5. Electrical equipment properly earthed and start/ stop switches within reach.
6. Exhaust hood or booth for belt, disc or orbital sander to collect saw dust.
7. Exhaust ventilation and spray painting booth while surface finishing with solvents and toxic
chemicals.
8. Prevention of fire hazard by close dust collectors as stated above, regular cleaning and
maintenance of machines, prohibiting smoking, good house keeping and using fire fighting
equipment.
9. PPE like leather aprons, goggles and gloves.
10. Medical check-ups for dust effects.

For an abstract of Schedule 3, Rule 54, GFR see Part 4.4 of Chapter-14..

Fundamentals of Industrial Safety and Health 23- 63 Safety in Construction Industry

 IS : Woodworking machines - safety conditions 8964 (Part I to 24), terminology 11011, working
dimensions 7287, working level heights 7229, mortising machine 7266, 7286, moulding machine 7254,
planning machine 7289, 7296, routing machine 8107, surface planning machine 7267, thickness planning
machine with rotary cutter 7249, table handsaw machine 7227, slot mortising machine 7266.

Woodwork - fire safety 6329, aluminium paint 3585, Wooden packaging - terminology 6703,
timber 6662, packing cases 1503, 6729, 8358, 4834, 3728, 8725, 8726, 7698.

Wood preservatives - 4873, 218, 4833.

Industries may be endless, as they are ever increasing with the human needs. A few are stated
above with more than 500 safety measures which give sufficient knowledge to find out safety measures
for other industries also. Chapters' 14,18,20,21 and 22 cover major part of machine guarding and safety
aspects of all mostly used processes and provide a data bank for effective safety inspection of any
industry.

EXERCISE

1. What are the health hazards of pesticides and methods of their control?
2. What are the main health hazards in cement industry? Briefly discuss the safety measures of safe
guarding the health of workers in this industry.
3. State the main hazards which are generally encountered in the storage and handling of solvents in
a petrochemical plant. Give their important preventive and control measures.
4. Explain the statutory provisions on manufacture of:
(1) Asbestos. (2) Benzene. (3) CSz (4) Glass. (5) Flammable liquids and Gases. (6) Rubber. (7)
Pottery. (8) Wood working. (9) Solvent Extraction plant.
5. Explain in details the health and safety measures on Chemical Works OR Hazardous Chemicals
and Processes.
6. Write short notes explaining safety measures :
(1) Types of industries needing attention. (2) Cement industry. (3) Electroplating industry. (4)
Fertiliser industry. (5) Leather industry. (6) Paper industry. (7) Plastics industry. (8) Polymer
plants. (9) Ship breaking industry. (10) Sugar industry. (II) Carcinogenic Dyeintermediates (12)
Tobacco industry.
7. Enumerate safety measures required in -
(1) Food industry. (2) Match factories. (3) Electronics industry. (4) Automobile industry. (5)
Beverage industry. (6) Brick or Tile industry. (7) Clothing industry. (8) Dairy industry. (9)
Petroleum refinery. (10) Ovens & Driers. (11) Soap industry (12) Silk industry.

Reference and Recommended Reading

1. Encyclopaedia of Occupational Health and Safety, ILO, Geneva 2

2. Accident Prevention Manual for Industrial Operations, NSC, Chicago, Illinois.
3. Loss Prevention in Process Industries (Vol. I and 2), Frank P. Lees, Butterworths.
4. Inspection Remarks of Inspectors of Factories and other Safety Authorities.,
5. The Factories Act and Rules of Gujarat, Maharashtra and Tamilnadu
6. Synopsis of the Gujarat Factories (Amendment) Rules, 1995 by K. U. Mistry, Siddharth
Prakashan. Ahrnpdahad.
7. Safety and Health in the use of Agrochemical: A guide, ILO, Geneva.
8. Standard specifications of different size Sugar Plants - National Federation of Co-operative Sugar
Factories Ltd., New Delhi - 110049.

Fundamentals of Industrial Safety and Health 23- 64 Safety in Construction Industry

9. Low - Cost-ways of Improving Working Conditions:- 100 Examples from Asia by K. Kogi, W.
Phoon and J.E. Thurman, By ILO
10. Safety and Health in the Construction of Fixed Offshore Installations in the Petroleum Industry,
ILO
11. Petroleum Production Handbook (2 Volumes), by Frick, McGrow Hill Book Co.

Fundamentals of Industrial Safety and Health 23- 65 Safety in Construction Industry