Accident prevention & Safety Management

Accident Case study
 Hand entangled with concrete pump
The worker hand was crushed when he put his hand to clean the pipe
chamber.

22 May 2014 3

Principles of Safety Management

PRINCIPLE : 1

• An unsafe act, an unsafe condition, an 
accident; all these are symptoms of 
something wrong in the management 
system.
 Principles of Safety Management
PRINCIPLE : 2

• Certain sets of circumstances can be 
predicted to produce severe injuries.  These 
circumstances can be identified and 
controlled:

Unusual, non-routine High energy sources, certain

Nonproductive activities construction situations

Principles of Safety Management
PRINCIPLE : 3

• Safety should be managed like any other 
company function.
• Management should direct the safety effort 
by setting achievable goals, by planning, 
organising and controlling to achieve them.
 Mr. Double Standard Management

Safety Production

Drama
Banner
Seminar
Essay
Competition

Principles of Safety Management
PRINCIPLE : 4

• The key to effective line safety 
performance is management 
procedures that fix accountability.
 Good safety
R+ suggestion Joe! Keep
bringing ‘em up!

One more report like

this and you’re outa
here!!

R-

Hand entangled with concrete pump
Accident findings
• Injured was a concrete pipeline laying worker
• Non routine activity, gange came for concreting
• Work started at 6.00am and completed at 4.00pm, then cleaning was taken up
immediately; incident took place at 4.30pm. Whereas site arrived at 9.00am to site.
• Concrete pump was cleaned in running condition, Cleaning rod was used sometime
• Accident occurred when cleaning is almost completed,.
• Operator went to operate the pump, meanwhile the Hiragiri was cleaning the
pumping chamber by hand

Cause of accident
• Concrete pump was cleaned in running condition
• Workers were neither screened nor safety inducted
• Safe work instructions were not imparted to new gang. Operating instructions and 
discipline is not taught to them
• Injured was not designated worker for cleaning the pump. 
• Workers were not safety inducted and Do & Don’t not briefed before start of work. 
• Supervision is effective

22 May 2014 10
 SAFETY & HEALTH 
MANAGEMENT SYSTEMS

Conforming to OHSAS 18001 : 2007
 S & H Mgt System Model
Overall vision, 
goals and 
commitment  •Legal compliance
to improve
Continual Improvement •Objectives and targets
•Implementation plans
 Suitable, adequate, 
effective
 Changes needed?
 Opportunities to 
improve?

OH & S Policy • Resources
• Leadership responsibility
• Training and competency
Management  • Consultation and communication
review • Documentation
• Hazard identification, risk assessment and 
Planning controls
• Emergency response

Checking and  Implementation 
•Monitoring and  corrective action and operation
measurement
•Incident investigation
•Records management
•Audits

Port Kembla Ethanol Tank Fire, NSW, Australia, 28th January 2004

Quote from the Coroner…“not a lack of adequate safety procedures but rather
the failure to adhere to them”.
(Welding was carried out in an unsuitable area without a ‘hot work’ permit)

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 Engineering

5 things you need to do
1. Be Safe ‐ Ensure you Personal Safety in Work Place

2. Be a role model 

3. Know your responsibilities in HSE 

4. Execute work safely 

5. Continuously update your 
Knowledge in HSE
 Health, Safety and Environment policy
Excellence in safety – nothing less
• We are committed to excellence in safety by ingraining a 
health, safety and environment (HSE) mind‐set into our culture
• We do this by always keeping safety as a top priority
• We act sustainably by facilitating safe working conditions and 
improved environmental performance for the users of our 
products and services
• The FLSmidth HSE principles and HSE responsibilities lead us in 
this important endeavor
Safety above all Environment
‐ make safety a daily priority ‐ Act sustainably
Competence and cooperation
‐ Share your knowledge
Return 18
 Site Safety Plan
• Safety Engineer prepares in 
consultation with RCM & 
Lead Safety
• Specific to project scope
• Implementation status 
review in Safety meetings
• Dynamic – Update 
frequently

Hazard Identification & Risk Assessment (HIRA)

List the activities

Identify the hazards
Determine risk
Estimate risk based on
Frequency & Severity
Measures to mitigate the risk

Return
Delegation Of
 Roles 
 Responsibilities
 Authorities
 Accountability

Site Engineer Safety & Health Line Of Command
Functions / Activities Responsibilities, Accountabilities and Authorities

Safety and Health  Establish Safety and Health requirements at workplace.

Management System  Implement the Safety and Health Management System as per this Manual.
 Understanding the Safety and Health requirements of the Project and following the
same in execution of the work.
 Participating in the Project Safety Inspection along with the Safety Engineer / Officer
or the committee Members
 Obtain work permit as per client requirements or company Safety and Health
Management System before starting work requiring a work permit.
Training  Responsible in selecting and engaging the workmen and ensuring that they are
engaged only after completion of screening system and Safety Induction
 Giving Tool-Box Talks to the workmen working under him highlighting the risk
involved in the task.
Planning  Participate in the preparation of Safety and Health Risk Assessment, safe work
method and implement the safe work method.
 Eliminating all unsafe conditions in their work area.
 Ensuring the workmen under him wear the necessary personal protective equipment
respective to the job.
Incident Investigation  Report all incidents to Safety Engineer immediately verbally and submitting the
and initiating CAPA preliminary incident report within 12 hours.
 Participate in investigation of all incidents and initiate necessary corrective and
preventive actions at sites.
Emergency Response  Informing the concerned authority as per the emergency response plan
 Safety & Health Line Of Command
Site Safety Engineer
Functions /
Responsibilities, Accountabilities and Authorities
Activities
Safety and Health  Facilitate in establishing Safety and Health requirements at workplace.
Management System  Ensure the implementation of the Safety and Health Management System and
norms as per the Safety and Health Management System and Safety Manual
respectively.
Training  Identify the training needs; design and impart training for staff, visitor,
subcontractors and workmen.
Legal  Monitor the evaluation of compliance to legal requirements as identified by the
Team Lead (Safety) at the prescribed frequency.
 Appraise the Project Manager / Resident Manager and Team Lead (Safety) on
matters of non-compliance and facilitate compliance.
Performance  Conducting periodical Site Safety and Health Inspections and report the finding
Monitoring for corrective action.
 Act as Secretary for the Project Safety and Health Committee.
 Review and appraise the site Safety and Health performance and facilitate for
improvement.
 Ensure the proactive performance monitoring through systems such as Key
Performance Indicator on Safety and Health.

Safety & Health Line Of Command
Site Safety Engineer
Functions /
Responsibilities, Accountabilities and Authorities
Activities
Planning  Preparing and updating Project Safety and Health Plan.
 Preparing Safety and Health Risk Assessment and Safe Work
Method.
Timely reporting of Safety and Health shortcoming to the project
manager for continual improvement.
Campaigns and  Organize campaigns, competitions and other special emphasis
Competitions programs to promote Safety and Health at workplace
Incident  Conducting investigation of all incidents and initiate necessary
Investigation and corrective and preventive actions at sites.
initiating CAPA  Analyze incident trends and initiate necessary corrective and
preventive actions at sites.
Emergency  Act as a catalyst for establishing, implementing and maintaining
Response emergency preparedness and response procedure at project sites.
Safety and Health  Reporting the site Safety and Health statistics.
Statistics
Training & Education Programs
Employees – Safety Training
• 3rd series of Safety training launched

Contractor workmen
New Workmen Safety Induction All 
Toolbox talks Daily basis
Trade specific Safety Training Quarterly basis

SITE SAFETY COMMITTEE

• HSE committee is constituted at
Site
• Resident Construction Manager is
the chairman, section heads are
members & Safety engineer is the
secretary of the committee
• Discusses and decides on matters
related to promoting safety at
Site
• Meets at least once in a month
• Reviews the implementation of
Project safety Plan; inspection
finding are discussed.
 General Safety Inspection Checklist
Erection Activity Safety Inspection Checklist
Scaffolding Safety Inspection Checklist
Working at Height Safety Inspection Checklist
Housekeeping Checklist
Electrical Safety Inspection Checklist

Safety  Diesel Generator (DG) Safety Inspection Checklist

Vehicle & Earth moving Equipment Safety Inspection Checklist
Inspections Crane Safety Inspection Checklist
Hydra Safety Inspection Checklist

Equipment Fitness Certification for Cranes

Equipment Fitness Certification for Vehicle and Earth
Fitness
Moving Equipment
Check27

Work Permit Systems

Construction Vessel or Confined Space Entry Permit

Excavation Clearance Permit
Hot Work Permit
Industrial Radiography – Information Form
Permit for Blasting Operation
Permit to Open Manhole Covers / Grills / Guardrails
Permit to Work at Height
Permit to Work at Night
Permit to Work on Plant, Machinery and Other Power Driven
Equipment
 Return
Motivational Schemes
Safety Rolling Trophy Scheme
Gifts for site achieving 1 Million & More Safe Man powers
Gifts for site receiving Client Recognition & Awards
Monthly Motivation prizes for workmen
Regular campaigns & competitions

Reprimand Measures are also adopted on need basis

Performance Measurement and Review 
Systems
• Internal Safety Audits
• Evaluation of Sub‐contractors
• Accident Statistics
• Key Safety Performance Indicator
 MANAGEMENT OF FIRST-AID
• Trained first aid Assts are
deployed at site
• First aid boxes are provided at
convenient location under the
charge of first aider
• First aid treatment is given to
injured person.
• If required the injured person is
shifted to hospital
• First aid injuries are registered
and analysed monthly

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ACCIDENT REPORTING SYSTEM

Reporting of all incidents
including Near-Miss &
Dangerous Occurrence

Maintain Record

Investigating Accidents

Analyze accidents

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 FLS India ‐ Safety Performance (2009 – 2011)
Manpower 
No of  Mandays Frequenc Severity 
Year worked
Incidents lost y Rate Rate
(Millions)
2009 9.3 12 26400 1.7 2823

2010 14.3 5 6400 0.35 444

2010 trend over previous year                                     Positive Trend

54% ‐58% ‐76% ‐79% ‐84%

2011 20.886 5 6179 0.239 295.7

2011 trend over previous year                                   Positive Trend

46% 0% ‐3% ‐32% ‐33%

Return

Material Cycle at Sites

Material unloading
& storing / stacking

Shifting of materials
Management of to site & using it for
Waste generated. HOUSE KEEPING the purpose which it
Removal / Disposal is intended

Removal of the
Materials &
Dispatching

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 SAFETY MANAGEMENT

Jobs That Are

Widow -Makers Are
To Be Thought And
Restructured
- Peter Drucker

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