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NEBOSH International General Certificate

in Occupational Health and Safety

UNIT IGC3: HEALTH AND SAFETY PRACTICAL


APPLICATION

Student Name:
Student Number:
Date of Submission:

APPENDIX 1
IGC3 The Health and Safety Practical Application
Candidate and course provider declarations:
For completion by the candidate:
I declare that the work submitted for this practical application assessment ie. the completed observation sheets
and the report to management, is my own work.
I recognise that contravention of this statement
constitutes malpractice and may result in my being subject to the penalties set out in the NEBOSH Malpractice
policy.

Name (Print)

Mohammed Musharraf M.Yunus Ansari

Signature
Date

10-01-2015

For completion by a course provider representative (e.g. internal practical assessor):


I declare that the work marked is identical to that received from the candidate. I recognize that contravention of
this statement constitutes malpractice and may result in my being subject to the penalties set out in the NEBOSH
Malpractice policy.

Name (Print)
Signature
Date
For completion by the course providers internal practical assessor:
I declare that I have marked this work and am both qualified and approved by NEBOSH to do so. I recognise
that contravention of this statement constitutes malpractice and may result in my being subject to the penalties
set out in the NEBOSH Malpractice policy.

Name (Print)
Signature
Date

NB: This declaration must be completed in full, submitted and retained with the
candidates script. If this declaration is not submitted the candidates result may be
declared void.

APPENDIX 3
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Assessors marking sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION
Date of practical application 10-01-2015

Name of assessor

Course provider
number

Course provider
name

Student number

Student name

Maximum
marks
available

Criteria
1

Completion of observation sheets

1.1

Range and number of hazards/good practice

15

1.2

Identification of suitable control measures and


timescales

15

Report - Introduction and Executive Summary

2.1

Introduction providing an overview of the chosen


area

2.2

Executive summary

Report - Main findings of the inspection

3.1

Quality of interpretation of findings and clear


references to strengths and weaknesses

3.2

Identification of possible breaches of international


standards

3.3

Persuasiveness / conciseness / technical content

10

Report - Conclusions and Recommendations

4.1

Clear and concise conclusions which are clearly


related to report findings and are effective in
convincing management to take action

15

4.2

Recommendations which present realistic actions to


improve health and safety in the chosen area

15

TOTAL MARKS

15

100

Assessors
marks awarded

NEBOSH
moderated
marks
(if different)

Outcome: PASS
Date assessed /

REFER (less than 60%)

(60% or more)

Assessors signature
Date received by course provider

Date received by NEBOSH


(if applicable)

Assessors additional comments on the practical application:

ASSESSED BY (name in block letters)


The mark sheet must be retained by the Course Provider and sent to NEBOSH only if requested.

NEBOSH USE ONLY


NEBOSH Moderators comments:

APPENDIX 5
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICAITON

Student number 00266623


Location

AMBANI CRUSHER

Date of inspection 10/01/2015

Management Report
Introduction :
The inspected site is a rock crusher in Ambarnath, Dist. Kalyan, and Maharashtra,
INDIA. The site visit was carried out on 24 th Nov 201 at 11:30 am; the name of site is
AMBANI CRUSHER. The fundamental function of a rock crusher is to smash bigger rock
objects and crush them to the desired size. The process starts by first passing bigger rock
objects into the crusher. There are various levels of crushing operations that are carried out.
Sometimes crushing is accomplished in a single crushing cycle. While sometimes the
process of crushing needs to be carried out until the rock objects are converted into dust
particles. Not all kind of engineering processes need the same level of crushing. Generally
the process begins with crushing big rock objects with a primary rock crusher; later those
crushed rocks are further crushed with a secondary rock crusher. These crushed objects may
be further crushed with a tertiary or quaternary rock crusher if the need arises.
Associated operations like breaking, loading, unloading of stones, grinding, welding,
cutting and maintenance job of plant etc.
It has around 100 employees are working including mechanic, electrician, operators,
drivers, subcontractors and others all work in only day shifts excluding securities staff, which
is outsourced and work day and night shifts. The rate of literacy amongst all workers is 55%.
There are 35% female employees in the staff.
The crusher which covers around 8000 sq.ft in area, having heavy plants and
machineries. Earth moving equipments and transport vehicles located inside and outside
the crusher. An office is located alongside with the crusher to facilitate the back office
requirements.

APPENDIX 5
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND SAFETY


PRACTICAL APPLICAITON

Student number 00266623


Location

AMBANI CRUSHER

Date of review 10/ 01 / 2015

Management Report
Introduction :

The main objectives of this inspection are to identify prevailing health and safety hazards,
to check level of health and safety standards and extent of complains of national and
international regulation and recommendations.

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION
Sheet number 01 of 13
Student name Mohammed Musharraf M.Yunus Ansari
Place inspected Am b a ni Cr us he r
Observations

Control measures

Hazards and consequences

1. In this company, transport


hazards are likely to happen.

Separation of Pedestrians
and vehicles by using
Barriers and designated

pedestrian and other structures in

Risk
(H,M,L)
H

Immediate
< 1 Week

walkways for pedestrian

the side.

serious injury even death

Timescale

Immediate and longer-term actions

Collision of vehicle to vehicle,

Consequences : could result in

Date of inspection 10/01/2015

should be provided.

Crossing lines, signs, speed


limits, markings, one way
system, warning alarms and

Within 2
Week

flashing beacons to be
implemented training drivers
properly & competency to be
ensured. Appointing banks
men for revering of vehicles.

2. Overturning of Damper trucks


due to over loading & over
speeding.

Proper training to the drivers,


authorized load to be loaded, Immediate
Banks men should be

Consequences: which will lead to

assigned while reversing,

serious injury even death, loss or

uniformly distributed load

damage.

and speed limits to be


enforced in the site, before
the work vehicle should be
inspected and maintained.

< 1 Week

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number 02 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

3. Employee working at height in


the crusher platform without any

Consequences: could result in fall


from height into crusher will lead to

4. Storage of raw materials in the


facility will lead to air borne dust.

Consequences: Installation of dust


could result in lung diseases, a s
phyciation even cancer course.

5. Conveyor belts, rollers in running

nip points can entangle, puncture,


impart, drawing and ejection, falling

objects from over head.


Consequences : Could result in

Timescale

Immediate and longer-term actions

safety precautions.

death.

00266623

serious injury or even amputation

Guarding & fencing the


crusher working platform,
and enforcing the are of PPE
like (Personal fall arrest
system, full body harness,
Dust marks, Hard hot, safety
gloves, goggles, safety belts
& lanyards)
PTW (Permit to work)

Risk
(H,M,L)
H

Immediate
2 Weeks

< 1 month

Training and Supervision


should be imported
Ensure cleaning of the area
and waste disposal in
allocated bins

M
Within 24 hrs.

Camping down the dust,


< 1 Week
maintain good house keeping
standards
Enforcing the use of Rpt in
the site

< 1 Week

Guards are fitted to machines Immediate


< 1 Week
and correctly adjusted and
used by operators to prevent
injuries
Emergency stop button,
Barriers, warning alarms or
sirens to alert the people that
the belt is about to start.

< 1 month

Information, Instruction &


< 1 week
Training to operator provided
Enforcing to use PPE

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number 03 of 13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

vibrations machinery to the


operator for a prolonged period.
Consequences : could result in
damage to the soft tissues of the

7. Workers working in hot weather


dentition for a long period of time.

dehydration,

heat

could

result

stroke,

Limit the duration of


exposure by job rotation.

Changing the work


techniques, shock absorber
and rubber bushes can be
provided to the crusher to
reduce vibrations

< 1 week

< 24 hrs

within
1 month

Workers should be given job


rotations.

plants of isoelertic fluids for


drinking provided.

shades should be provided to


work

< 24 hrs.

Frequent rest breaks


provided

< 24 hrs

fatigue and can fall from height

PPE should be provided

Risk
(H,M,L)
H

in

stress,

Reduce vibration at the


source and interrupt the
pathway from source to
receiver by Anti vibration
platform.

spine (disc prolapsed)

Timescale

Immediate and longer-term actions

6. Exposure to whole body

Consequences

00266623

< 24 hrs.
< 24 hrs.

< 1 week

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

04 of

Student number

Student name Mohammed Musharraf M.Yunus Ansari


Place inspected Am b a ni Cr us he r

13

00266623

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

Timescale

Immediate and longer-term actions

8. Long term, repeated to exercise

Isolation of the mechanical < 1 month

loud noise of the rotating parts of

rotating

the crusher.

machinery at its source itself.

Consequences : The repeated

excessive loud noise will effect the

Risk
(H,M,L)

and

heavy

noise

Workers should be enforced

<24 hours

to wear ear defenders

heating system and will lead to


permanent deafness
9. Spillage of oil and greaves which

Barricade the area and align


house. Keeping staff to clean
up using spike kits. Isolate
the area.

Train all workers to report the


spills

is used to lubricate the conveyor


rotating parts.
Consequences: could lead to a slip
injury or even death.

10. Manual Handling Operations by


for

lifting,

could

result

musculo skeletal disorders,


abrasions, hernias.

bending,

stooping & twisting of heavy weight.


Consequences:

< 1 week
On going
monitoring

and fall which will result in serious

workers

< 24 hrs
hours

in

cuts,

Good housekeeping should


be maintained.

< 24 hrs.

Weight of the loud to be


reduced, centre of gravity of
load to be checked.

< 1 week

continuing training to meet


changing requirements

< 1 month

Adequate lifting and moving


equipments should be
provided and PPE to be
provided

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

05 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

11. No fire alarm system

Timescale

Immediate and longer-term actions

installed, no five escape routes


marked, No assembly points are
not marked, no five
extinguishers placed in the
facility.

00266623

Consequence : During
emergency it could lead to
chaos and there is not
understanding of assembling

< 1 week
Five alarm system to be
installed, walkways risks
should be clearly marked,
Assembly points should be
away from the facility
where welfare facilities can
available. Well illuminated
exit signs to be posted.
Fire drills must be
6 months
conducted at least once in
at least
6 months for workers to get
acquainted with assembly
point and means of escape
fire extinguishers to be
installed.

Risk
(H,M,L)

points, fire extinguisher could


delay to rescue, if some one is
injured or trapped.

12. A 3 meter depth & open

ditch in the site for the washing


purpose of small stories doesnt
have a ladder for access and
egress, no barricading done, no
signage provided.
Consequences: man can fall,
while can fall could lead to
serious lying even death.

Barricading of the open


< 1 month
ditch should be done;
signage should be placed to
prevent the unauthorized
entry.
Controlling of the
movement of vehicles near
the ditch to avoid collapse
of the mud and vehicle fall
into the ditch.

< 1 week

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

06 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

13. Absence of protective guards

00266623

Timescale

Immediate and longer-term actions

Operator should be a
competent person to
handle the electric works

Closed circuit surveillance


system to be placed

< 24
hours

Use safe system of works


lock out/tag out system
during maintenance

< 24 hrs.

on the electrical control panel of


the crusher in the electrical

Risk
(H,M,L)

immediat
e one
week

room.

Consequences : open wires


could result in electrocution,
burns & five due to short circuit
and can lead to survey injury or
even death.

Signages(warning signs)

proper grounding of the


electrical equipment done.

14. Around the air there is no


barricading boundary or wall, No
green bell along side it.

Consequences : trespassing
and unauthorized entries can
result in hazards to themselves

Installation of ELCB, MCB,


RCCB
Appropriate fire
extinguisher should be
provided (Co2)
Authorized entry to the
control room

1 day
1 day
1 week
1 week
1 day
2 Months

Contain the site by


1 Week
permanent fence or bund
wall.
1 Week
Warning signs and notice on
the perimeter/wall
Designated entry/exit and
6 month
check point for vehicles and
workers
Develop green belt around

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

07 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

15. Observe workers resting and

lunch room. Rest room, Changing

Stop worker to have lunch

Consequences : Unwanted

Temporary make shift of


be raised

hazard exposure while resting,

deterioration in morals of
workers

should be provided.

Use of PPE Should be

PPE when working in a noisy and

enforced, training of PPE for

dusty environment where rocks

all workers.

are crushed into pieces


17. No appropriate tools to clear

wooden stick to remove it.


Consequences : Pinching, cuT,

Provision of crowbar, hooks


or specialist tools to remove
blockage

Appropriate devices to
break the stone in place

Installation of rock breaker


above jaw crusher

Emergency stops control


and Alarms

Implementation of
Procedure and
supervision(JRA,PTW)

abrasion and crush injuries to


hands, finger, snatching of tool
from hand leading to
musculoskeletal injuries. Due to
twisting stooping & repetitive
movement.

<1 week

1 month but
2month
Immediate
1 week
H

4 days

blockage from jaw crusher,


worker has to use hand and

Immediate

not more than


Permanent separate rest
room with all basic facilities

16. Operator not wearing any

Risk
(H,M,L)

and rest near work

tins of mock in tool should

contamination of food,

Timescale

Immediate and longer-term actions

having lunch around the plate


and machineries as there is no

00266623

1 week
1 month

1 week
1 month

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

08 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

18. House keeping of the entire

00266623

Timescale

Immediate and longer-term actions

Oil and diesel spilling to be Immediat

crusher is very bad and oil and

removed immediately using e 1 week

diesel spillages, troulders lying

spike kits. Dispose them in

all around the floor and on

the allocated metal bins

walkway

Consequences : Slip and fall

Risk
(H,M,L)

< 1 week

Maintain good house


keeping standard

< 1 week

hazard; could result in severe


injury

19. Dragging and Sliding of O2

Cylinders should be moved

oxygen cylinder in the facility,

using trolleys, which is

while dragging or sliding there

chained to secure the

are chances of accidental fall

cylinder to avoid tipping.

< 1 week

due to manual handling.


Consequences : If it falls, the
nozzle of the cylinder breaks and
the cylinder will act as a missile
and can penetrate walls and can
hit peoples which could result in
death

Training and Supervision


provided

within 1
month

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number 09 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

20. Ejecting particles from the

Timescale

Immediate and longer-term actions

rotation of crusher rotor


Consequences : puncture or

00266623

Fixed guards for all rotating

Risk
(H,M,L)

< 1 month

parts to be installed

Inspection by a competent

stabbing, enlargement of hand,

person to check whether

drawing in can lead to

the guards provided are in

ambutation of the limps

place or not by using a

< 1 week

checklist.

Training and Supervision of


level of knowledge and
skills.

< 1 month
< 1 week

PPE like , safety glasses,


RPE, Hard hats, Safety
shoes, Safety gloves, and
ear defenders should be
provided

21. Emission of Dust from the


Crusher

< 1 month

A crusher fact box with a

Consequences : Inhalation of

minimum number of

dust can cause silicosis

openings is installed. The


crusher should be choke fed
to reduce air entrainment &
dust emission

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

10 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

22. There are adequate numbers


of

clean

toilets

and

00266623

Timescale

Immediate and longer-term actions

Good Provision

Provision of metal ladder


with guard rails angled
between 70-75 degree
Construction of permanent
stair steps at least 75 cm
wide permanent stories
steps at least 75 cm wide

Risk
(H,M,L)

urinals,

separate for males and females

23. No safe access and egress


into the boulder pit, worker has
to

climb

up

and

boulder

down

the

piton(sloping

arrangement of stone) which is


slipping, very steep
Consequences: Slip, trips and
fall from height, musculoskeletal
injuries.

Instruction to use trailing


hand technique or three
point contact while
ascending/descending only
one step at a time.

1 week
1 month

< week

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number

11 of

13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

24. Found damage and exposed


electric line on the surface of
road, due to frequently plying

00266623

Timescale

Immediate and longer-term actions

Isolation notice

Electric cables should be

Risk
(H,M,L)

Immediate
24 Hrs

laid into the ground in shock

trucks.

proof materials or should be


Consequences : Shock, electric

taken over head

bush, electrocution and death.


Tripping of power supply to the

Provision of extra plastic or

plant loading to stalling

insulating conduits to run

(stoppage). Tripping and fall of

cables, and good quality

pedestrian

cables, desire system of


check and maintenance

25. In the crusher office room


due to excess of height of

Assessment of workstation

Provision of appropriate size

desk(Tally, clerk workstation) and

of desk and chair with

ill positioning of keyboard,

adjustable back and height,

computers, the operator is

tiltable keyboard.

exposed to WRULD (Work related


Upper Limit disorder)

26. Adequate illumination has


been provided in the work place

Information of ergonomics

Good Observation

2 week.

Immediate
1 week

1 week

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number 12 of 13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 10/01/2015

Observations

Control measures

Hazards and consequences

00266623

Timescale

Immediate and longer-term actions

Risk
(H,M,L)

27.Observe no guards on
conveyor and tail pully.

Fitting of protective guards


on all rotating and moving

Consequences : Major or serious

Immediate
<1 week

machinery

injuries due to drawing in,


running in, entanglement

Warning signals to alert the

pinching, fall of atom from

worker that machine is

running conveyor belt, even

going to start shortly

amputation of finger.

Emerging stop button and

<1 Week

< 1 week

easily accessible controls

Information instruction,

<1 Week

training of safe working and


use of PPE
10 days

28. Hot surfaces of several


machineries posing risk of burn to
workers

Placement of signs and


notices

Provision of insulating

2 months

materials and guards of hot


Consequences : Burn, Burn

surfaces

injuries, blisters, heat, heat


exhaustion, fire hazards.

Provision of cooling system


on stone crusher

Provision and use of


PPE(Overall, gloves, shoes,
hate, etc.)

1 Month

APPENDIX 4
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICATION

Sheet number 13 of 13

Student name Mohammed Musharraf M.Yunus Ansari

Student number

Place inspected Am b a ni Cr us he r

Date of inspection 01/01/2015

Observations

Control measures

Hazards and consequences

29. No warning notice plates &

Timescale

Immediate and longer-term actions

Inform staff of risk, restrict

signs are placed on the hazards

the entry by barricading

location and escape route.

tape

Consequences : Imminent

00266623

Risk
(H,M,L)

Immediate
H

1 Week

Install notice plates and


signs at designated

hazards and fatal accidents and

locations

grief injuries. This could create


Chaos during emergency.

30. No first aid boxes and


medical help available on the

2 days

site,

Allocation of responsibilities
to check and update first aid

Bad prognosis of injuries Delay in


revival of victims
More fatalities in work place.

2 days

at appropriate locations

Consequences :- Delay in
administration of first aid.

Installation of first aid boxes

boxes

Awareness program of how


to administer first aid and
contacting emergency

2 weeks

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Executive summary
The fundamental responsibility of management is to ensure that safe system of
work is prevailed in all areas of crushers that pose the significant risk to life, property
and overall environment.
The crusher is not maintaining any of the safety standards to protect the
workers and public from any eventualities, major violations like Signage, fire, safety
equipments, PPE, Safety shoes, respirators, Safety dust masks, Helmets, Coverall,
Gloves, which is major violation as per the ILO OSH 2001 convection and the Indian
factory act 1948.

The

management

is

not

committed

towards

safety;

and

are

ignoring

the

responsibilities towards safety of his workers and the public, as the crusher is equipped
with highly dangerous plants and equipments which are not guarded properly and safe
guarding of the employees also neglected, which is not accepted locally and
internationally. The company doesnt have a HSE management policy and system and
there is no standard organization which is entrusted with setting up, safe place to
work, safe systems of work (safe procedures, Permit to work system, Risk assessments,
Guidance notes). The organization doesnt have a safety officer/safety manager to
manage the HSE system to ensure the work place is safe and the legal compliance are
met, the most importantly induction training and other supervision of the job sites,
Auditing by a external agency has not conducted to ascertain the standards and since
there is no policy, the question of review doesnt exist.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Executive summary
Upon initial assessment of various locations of the crusher, the findings are as follows.
Lack of management commitment and leadership towards promoting a positive safety
culture in the organization, this should be from the senior managers, especially at the
top of the organization to the bottom. Senior managers must provide the leadership
necessary to inspire and motivate managers at all level to pursue health and safety
objectives rigorously.
Violation of safety rules, such as unawareness of safety, no safety systems in place, no
defined roles and responsibilities, new employees are not given any form of induction
and orientation of the work place. Violation of Indian factory act 1948 for not providing
basic PPE at free of cost to employees. The line managers are not aware of the hazards
and the risks associated with the crushers plants and its equipments, power and
electricity, distribution systems and people and environment.
Other major violations like absence of Guards of machinery and dangerous
objects recommendations of ILO-OHS Convention C150 and occupational safety and
health act 1970.

No line of reporting and notification, violation of ILO-Code of

practice for recording and notifying of occupational accidents and diseases.


There is no H & S representative on the site to help maintain and implement
health and safety system.
The management is oblivious of hazards and risk associated with plants,
machinery and activities in the site, if timely corrective and preventive action not taken
fatal accidents may result and legal action may ensure.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


Please find herewith some of the high priority hazards that

were observed which

needs immediate attention


1.

No designated pathways and walkways for entry/exit vehicles carrying heavy


loads and pedestrians no segregation between pedestrian and vehicles
maintained. Could result in collision and lead to death or fatality.

Control Measures :
The traffic system in the company is not controlled properly and a number of
transport hazards were present as a result of unsatisfactory working practices, rash
driving pedestrians crossing were vehicle movement are more, and collision with other
means of transport. These represent possible breaches of the employers obligation to
provide and maintain a safe workplace and provide safe work equipment, as stated in
Article 109a) of R 164
In long term, Management should ensure that proper routes for vehicles and
pedestrian that can be done by, when segregation is possible, should provide a
designated walk-way which should be barricaded and clearly marked and should
ensure and enforce the work site rules.
In short term when segregation is not possible, zebra crossing lines, speed
limits, humps, one way traffic systems, audible alarms and flashing beacons, warning
signage, assigning of banks men to be implemented and monitored.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


Approximate Budget (Capex)
Procurement cost for barricading and enforcing site rules = Rs. 175,000.00
Awareness training
2.

=Rs. 15,000.00

Workers working at height without any PPEs could result in fall from height in
to running crusher and lead to death of fatality.

Control Measures :
Proper guard rails of working platform and enforcing use of Personal Protective
Equipments like personal fall arrest system (Full Body harness with lanyards), safety
goggles, hard hats, respirators, safety shoes, coverall, safety gloves, and ear mufflers.
As work at height is considered as high risk activity and must ensure the safe system
of work, permit to work system by competent personnel with continual training and
supervision. As per ILO convention (155) the above mentioned are the responsibilities
of the employer for high risk works. Violation of the above act leads to legal penalties
and which could adversely affect the organizational reputation.
Approximate Budget (Capex)
Installation of guard rails of working platform = Rs. 45,000.00

Basic PPEs (people working at height) = Rs. 25,000.00

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND SAFETY


PRACTICAL APPLICATION

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


3.

Exposed rotary parts of crusher plant and machinery could lead the workers to

entanglement, entrapment, drawing in, puncture and stabling g impact and falling
objects from overhead will lead to very serious injuries result in limbs amputations or
even death. Several items of the machinery and equipments, hot surfaces open pullies
and conveyors are in dangerous condition due to the absence of guarding, poor
maintenance.
These represent possible breaches of the employers obligation to provide safe
work equipment that is safe and without risk to health, as stated in Article 10(a) of R
164

Control Measures

In short term; management should ensure that a safe system of work, a tool box
talk by the safety officer/site supervisor should be conducted to highlight the dangers
of using unguarded machineries and defective equipments.
In the long term; management should ensure that, proper guards should be provided
at all rotating parts of the conveyor belt machinery, safe guarding devices like
emergency stop, safety devices like sirens, warning alarms. Proper PPEs and
implement safe system of works (informations signage & instruction lock out/tag out).
A part from the above measures, proper training and supervision required. Welfare
facilities like assigning a competent first aider and first aid boxes should be readily

available, Reporting system and workers should instructed in the importance of


reporting hazards immediately, competency of the staff should be ensured.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


As per Indian factory act 1948 & ILO-OSH 2001 employer has the responsibility to
provide a safe work place, safe plant and equipment, safe system of work, training and
competent staffs.
Approximate Budget (Capex)
Installation of guards for conveyor belts
Safe guarding devices

= Rs. 1,00,000
= Rs. 50,000

Basic PPE

= Rs. 30,000

Awareness training

= Rs. 13,000

Signage

= Rs. 2,000

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection

4.

As the facility is involved in various electrical equipments and a number of five

hazards were present, including the storage of diesel and other fields for vehicles and
machineries. The organization doesnt have the provision of reporting emergencies
such as fire, chemical spill, toxic substance release and other emergencies,
organization neglected the fire safety norms in the entire facility. The organization
doesnt have five safety plan, emergency action plan and excavation map and there is
no marked fire escape routes, fire extinguishers, fire alarm systems, call points. Which
could lead to major disaster and causalities in the event of emergencies, this is not
accepted worldwide.

Control Measures :
A good housekeeping should be maintained. Waste management system to
implement and unwanted things to be disposed. Storage of diesel and other fluids
should be in appropriate container and should be separated by ignition sources. All
electrical equipments should be inspected and maintained before the work.

Fire alarm systems to be installed, Fire extinguishers and fire hose reels to be
implemented. Fire plan and emergency plan to be developed and should be posted
where 10 or more employees can see it. Fire safety training and periods fire drills to be

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


conducted at least in 6 months, safe place for vulnerable peoples. Fire warden should
be assigned to look after the fire safety compliance and assist vulnerable workers for
safe evacuation. As per OSHA it is mandatory to provide fire safety training for all the
employees and evaluate the drill for continual improvements.
Approximate Budget (Capex)
Installation and commissioning of fire alarm systems
Procurement of fire extinguishers
5.

- Rs. 1,45,000
- Rs. 60,000

Exposed electrical distribution system for heavy electrical equipments in


control room and damage electrical cables. There could be a possibility of
electric shock to the operator which can lead to severe injury or death. The
organization does not have any protective devices installed like ELCBS, MCBs
and grounding system to protect the worker and the equipment from
electrocutions.

These represent possible breaches of the employers obligation to provide safe work
equipment that is safe and without risk to health, as stated in Article 10(a) of R 164

Control Measures
Short term :

Management should ensure that a safe system of work (lockout/tag

out procedures). All electrical distribution systems like panels, input and output
wiring/cabling, terminations and isolations should be inspected and maintained prior to
work. Competency of the staff to be ensured. Management should ensure that proper
insulated electrical tools to be provided. PPEs suitable for electrical applications should
be provided.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


Long term :
electrical

Management should ensure that proper protective guarding for five

distribution

systems

in

the

control

room,

which

includes

proper

conducting/traying for the input and output cables, installation of protective systems
like ELCB/MCB, RCCB, electrical warning signage, appropriate fire extinguisher (Class
E), proper grounding and insulation as per equipments manufacturers information,
should ensure authorized entry and restrictions to the control room.
Approximate Budget (Capex)
Installation of ELCB,MCB,RCCB

- Rs. 1,00,000

LOTO Equipment & Conduiting all trained cables

- Rs. 65,000

6. Workers doesnt have any lunch cum rest room, changing room and toilets on
the site, worker were eating their lunch under the shades of machinery and plants.
They dont have separate rest cum lunch room to eat and relax. In this way they are
exposed to unforeseen hazards and contamination of foods.

Control measures
Management with immediate effect should stop workers to rest and have lunch
in the vicinity of plants or in work place. Separate permanent rest room should be
made or for time being the moveable cabin (pota cabin) should be arranged or
makeshift of shed should be erected away from work place.
Basic welfare facilities are right of workers, provided by employer as per Labor
act 1975 and WHS & W-Workplace, Health, Safety and welfare regulation 1992, failure
to do so may lead to cancellation of license

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10/01/2015

Main findings of the inspection


Approximate cost for permanent rest room, toilet with all amenities could be 5
lacs. Though the amount is more but resultant benefits will be more, as healthy
workers, happy and satisfied worker, and increase in production.

APPENDIX 5
INTERNATIONAL
GENERAL CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL
APPLICAITON

Student number 00266623


Location Ambani Crusher

Main findings of the inspection

Date of review 10/01/2015

7. First aid boxes and resuscitation kit are not available on the site. No provision of
medical health and untrained staff can lead to major fatalities.

Control measures
Short term - Installation of first aid boxes and provision of resuscitation
Long term :- Allocation of responsibilities to check and update the medical facilities.

Approximate Budget (Capex)

Installation of First aid boxes

- Rs. 1,00,000

Provision of resuscitation kit

- Rs. 1,50,000

Total

- Rs. 2,50,000

APPENDIX 5
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)
Student number 00266623

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICAITON
Location

Ambani Crusher
Date of review 10/ 01 /_2015

Conclusion:
Management of this company should wake up and accept the reality that a
massive turnaround is needed to bring about the safety culture changes in this
organization. It is hoped that this will inspire and facilitate increased cooperation,
innovation and commitment to preventing hazards and committed and to be a role
model and start immediately by implementing a safety policy which will suits the nature
of business, first of all should consider to employ at least one safety officer to begin
with, and set out realistic aim and objectives, rolling out to tackle the high priority risks
and to implement control measures and then step by step reduction to be achieved.
In order to combat the problem, though, there needs to be close coordination and
collaboration, using a holistic and integrated approach to address the outlined findings.
While these findings are predictable and therefore preventable. There are many
interventions that can save lives and limbs, political will and commitment are essential
and without them little can be achieved. The time to act is now. Complete segregation
should be done between the vehicles and pedestrians and should ensure that all
workers adhere to the site rules; training for drivers must be undertaken and supervised
should be reviewed as necessary. The is most priority issue of the employer of
considering the safe place of work, safe plant and equipment, safe system of work,
training and supervision and competency of the staff must be ensured and reviewed as
necessary.
Fire safety plan, Assembly point, means of escape, Fire fighting equipments and
proper training for all workers should be taken on priority and periodic fire drills to be
conducted to attain proficiency.

APPENDIX 5
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICAITON

Student number 00266623


Location

Ambani Crusher
Date of review 10

Recommendations:

Sr.No.

Finding

Recommendation

Likely

Procurement cost for barricading &


1

Resource Priority

Target Date

Implications

Ref. No

/__01___/__2015_

enforcing

site

rules

Awareness

training

Rs.

1,75,000.00

Rs.

15,000.00

High

30/11/2012

High

3/12/2012

Total - 1,90,000.00
Installation of guard rails of working
2

platform Basic PPEs (People working


at height)

Rs.

45, 000.00

Rs.

25,000.00

Total

70,000.00

Installation of guards conveyor belts.

Rs.

1,00,000.00

Safe guarding devices

Rs.

50,000.00

Basic PPE

Rs.

30,000.00

Awareness training

Rs.

13,000.00

Signage

Rs.

2,000.00

High

29/11/2012

Total 1,95,000.00

Anti vibration mats.

Rs.

18,000.00

Installation of shock absorbers and

Rs.

85,000.00

rubber bushes

Total 1,0,3000.00

Medium

30/11/2012

APPENDIX 5
INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10 /__01___/__2015_

Recommendations:

Sr.No.

Finding

Recommendation

Isolation of crushers rotating


8

fire alarm systems.


11

Rs.

Procurement of fire extinguishers


Training personnel in use of fire
extinguisher

Rs.

1,45,000.00

Rs.

60,000.00

Rs.

25,000.00

13

LOTO Equipment & Conducting


all trailed cables

Medium

20/12/2012

High

30/11/2012

Total 2,30,000.00

Installation of ELCB, MCB, RCCB Rs.


7

Target Date

1,55,000.00

part(Acoustic proofed material)


Installation and commissioning of

Resource Priority

Implications

Ref. No

Likely

Rs.

1,00,000.00
65,000.00

High

28/11/2012

Total - 1,65,000.00
8

10

18

Procurement of spill kits

Rs.

15,000.00

Trolley for moving of cylinders

Rs.

4,500.00

19

17

Crowbar, Hooks, Rod

Rs.

70,000.00

Stone breaking devices

Rs.

1,00,000.00

Total

1,70,000.00

Lunch cum Rest room with all Rs.


11

15

APPENDIX 5

amenities, changing room & toilets

Medium

30/11/2012

High

30/11/2012

High

29/05/14

Low

26/06/14

3,00,000.00

INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

UNIT IGC3 THE HEALTH AND


SAFETY PRACTICAL APPLICAITON

Student number 00266623


Location Ambani Crusher

Date of review 10 /__01___/__2015_

Recommendations:

Sl.No.

Finding

Recommendation

13

25

23

Resource Priority

Target Date

Implications

Ref. No

12

Likely

Desk

Rs.

15,000.00

Testable keyboard

Rs.

07,000.00

Total

22,000.00

Metal ladder with guardrails

Rs.

50,000.00

Construction of permanent stairs

Rs.

1,00,000.00

Medium

31/05/14

Medium

20/06/14

High

02/06/14

High

1/06/14

Medium

1/06/14

Total 1,50,000.00
Barricading of walkways & side
14

14

Rs.

2, 50,000.00

Rs.

70,000.00

boundaries.
Development of green belt around
the site

Total 3,20,000.00

15

Seat belts fixing

Rs.

50,000.00

Rollover protection

Rs.

1,10,000.00

Total 1,60,000.00

16

30

First aid boxes

Rs.

1,000,00

Resuscitation kit

Rs.

1,50,000.00

Total

2,50,000.00

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