03 - Physical Injury and Controls 1

OCCUPATIONAL SAFETY AND HEALTH
(BDA 31302)
Chapter 3:
PHYSICAL INJURY
AND CONTROLS
Compiled by:
Assoc. Prof. Dr. Sh Salleh Sh Ahmad, Assoc. Prof. Dr. Musli Mohammad,
and Dr. Mohd Nasrull bin Abdol Rahman
Universiti Tun Hussein Onn Malaysia (UTHM)
DISCLAIMER
The information contained in this document is compiled from various sources and provided on an "AS IS" basis for teaching and learning
purposes only without any representations, conditions or warranties whether express or implied, including any implied warranties of satisfactory
quality, completeness, accuracy or fitness for a particular purpose.
Chapter 3
PHYSICAL INJURY AND CONTROLS
3.1 Introduction to Physical Injury

BDA 31302 Occupational Safety & Health
Definition of Injury
• an act or event that causes someone or something to no
longer be fully healthy or in good condition
• an act that damages or hurts
• Legal definition; an act that wrongs or harms another;

specifically : a violation of a legally protected interest
(as the physical or mental well-being, property,
reputation, or rights of another) for which the law allows
an action for legal or equitable relief
Definition of Physical Injury

• Injury is damage to the body.[1] This may be caused by
accidents, falls, hits, weapons, and other causes.[1]
• Major trauma is injury that has the potential to cause

prolonged disability or death.
[1] Jump up to: a b "Wounds and Injuries: MedlinePlus". Nlm.nih.gov.

Retrieved 2015-07-20.
Cover physical injury and control

at :
• 3.2 Construction Work
• 3.3 Electrical Work
• 3.4 Mechanical Work
• 3.5 Chemical Work
• 3.2 Construction Work
• 3.3 Electrical Work

• 3.4 Mechanical Work

• 3.5 Chemical Work

Chapter 3
3.2 Construction Work

Learning Outcomes
At the end of this section, students will be able to:
• Explain the building operations according to the
FMA 1967
• Describe at least 6 construction site hazards
• Explain the types of accident at construction site
• Plan the strategies that can be implemented in
managing the safety at construction site
• Relate the requirements of FMA 1967 and OSHA
1994
Definition of Building Operations (FMA 1967)

• “Building operations” means the construction,
structural alteration, repair or maintenance of a
building including repointing, redecoration, and
external cleaning of the structure, the demolition
of a building, and the preparation for and the
laying of foundation of an intended building.
Legal Requirements
Occupational Safety and Health Act 1994
• General duties of an employer
▫ To appoint a safety and health officer
▫ To formulate safety and health
▫ To provide safe work procedure
▫ To set up a safety and health committee
Legal Requirements
Occupational Safety and Health Regulation
(Safety and Health Officer) 1996
• The need to appoint a safety and health officer at
workplace if the value of the project is more than
RM20 million either for:
▫ Building operations
▫ Work of engineering construction
Legal Requirements
Factory and Machinery Act 1967
• General provision related to certified machinery,
installation and employees
• Factory and Machinery Regulations (Building
Operations and Work of Engineering
Construction) (Safety) 1986
▫ Provision related to safety and health for
activities, equipments and employees
Activities at construction sites

• Excavation
• Piling
• Concrete work
• Demolition
• Brick laying
• Installation of electrical cable and pipe
• Welding work
• Handling of construction material
Machineries / equipments at
construction sites
Machineries / equipments Purposes
Crane (Tower / Mobile) / Skip hoist Lifting goods and material
Passenger hoist / Gondola Lifting employees
Bending machine Bending steel bar
Cutting machine Cutting steel bar, wood and plywood
Excavator Excavation work
Piling machine Piling work
Lorries/Trucks Transport the construction materials
Batching plant Concrete processing and delivery
Other tools:
• Hand held / portable tools (hammer, chisel,
drill)
• Ladder
• Scaffold (fixed and movable)
• Air Compressor
• Hammer Drill
• Generator
• Welding set
Machineries / equipments require
certification from DOSH
Crane (Tower / Mobile) Pilling machine and structure
Passenger hoist Skip Hoist
Gondola
Air compressor Material Hoist
Lift Aerial Platform
Hazards at construction sites

Heat stress Ergonomic problems
Noise Biological
Mineral dust Elevated working area
Machineries Working at close compartment
Electrical Lighting
Radiation Drown
Chemicals
Types of typical accidents:

• Falling from elevated area
• Falling within same floor level
• Struck by fallen object
• Buried by collapse cliff / earth / fallen structure
• Electrical shock
• Drown
• Hit by vehicles
• Inhalation of toxic chemical
• In contact with rotating machines
• Caught between two objects
Falling from elevated area is normally associated

with the following:
• Ladder
• Working platform
• Roof (top of building)
• Through floor opening
• Open edge
• Scaffold
Factors that cause falling from elevated area:
• No wall or fence at working area

• Working area / equipment is not properly maintained
• Working area / equipment is not inspected before
starting work
• Equipment installer is not competent
• Employees are not provided with safety belt
• Improper design / structure of ladder
• Usage of damaged ladder / scaffold
• Usage of inappropriate ladder / scaffold
• Inappropriate position of ladder / scaffold
Falling from the same level is normally associated with the following:
• Legs getting caught with wire or hitting material on the floor
• Slippery floor
• Causal factors:
▫ Improper housekeeping at work area
▫ No housekeeping activity
▫ No equipment storage area
Causal factors of getting struck by fallen object:

▫ Improper housekeeping at work area
▫ No toe-board at the edge of the working platform
▫ No overhead protection
▫ No safety net
▫ Unsafe lifting method
Buried by collapse cliff / earth / fallen structure is normally associated
with:
• accident happened during excavation work for the purpose of
scaffold or formwork installation
Causal factors:
▫ No earth support installation
▫ No work guidance or safety work procedure
▫ Overloaded
▫ Structure design error
▫ Usage of damaged or inappropriate scaffold
▫ Improper position of scaffold
▫ Working area / scaffold is not properly maintained
▫ Working area / scaffold is not inspected before starting work
▫ Scaffold installer is not competent
Causal factors of electrical shock:
▫ In contact with electric current due to damage cable insulator
▫ Usage of damaged or modified electrical equipment
▫ No earth wire
▫ No safety device at the electrical equipment
Drown is normally associated with:

• Confined working area (tank, sewerage pipe)
▫ Lack of oxygen
• In water pond
▫ Swallowing water
• Causal factors:
▫ Insufficient air ventilation
▫ No exhaust air suction system
▫ No work guidance or safety work procedure
▫ Presence of too much water
▫ Employees are not trained and lack of experience
Causal factors of getting hit by vehicles
▫ No dedicated pathway for employees / pedestrians
▫ No barrier / fencing separating employees and vehicles
▫ No traffic rules and enforcement in working area
▫ No inspection on vehicles
▫ No vehicles maintenance
▫ Untrained and inexperience driver
Inhaling toxic chemical

• In painting and welding activities
Causal factors
▫ Failure to use appropriate respirator
▫ Insufficient ventilation
▫ No air exhaust system
▫ Employees were not appropriately trained
In contact with rotating machine parts or caught between objects
Causal factors
▫ No guard or fencing
▫ Using damaged guards or fencing
▫ Improper employees training
▫ Inappropriate guards or fencing design
▫ Guards or fencing are not at strategic location
Safety and health management

The strategies:
• Establish Safety and Health Committee
• Identify work place hazards
• Assess the hazards risk
• Plan and organise safety and health action
Safety and Health Management within Employers controls:

• Formulation of safety and health policy
• Employ safety and health officer (depending on project value) or site safety
supervisor
• Establish and enforce work place safety and health rules
• Issuance of permit to work for high risk activities
• Provide supervision for high risk activities
• Provide safety and health induction training for all employees
• Provide personal protective equipment and ensure its usage by all workers
• Establish safe work procedure for all activities
• Provide appropriate and safe equipment
• Select and appoint competent and well-trained person for high risk activity such as
crane operators or working at elevated area
• Investigate on all accidents and near misses
• Conduct inspection at the work place
• Establish communication system to allow and encourage employees feedback
• Establish periodical preventive maintenance for all machines and equipments
• Display safety warning signboards
Class Activities/ Discussions

• Explain the building operations according to the FMA
1967.
• Describe 6 construction site hazards.
• Explain the types of accident at construction site.
• Plan the strategies that can be implemented in managing
the safety at construction site.
• Relate the requirements of FMA 1967 and OSHA 1994.
Conclusions
• Involvement of various activities at construction sites
resulted into many hazards with potential to cause
accidents
• There are established regulations related to safety and

health under FMA 1967 and OSHA 1994
• Employers must manage the safety and health aspects in

order to ensure the employees safety and health as well
as obliging to the law.
Chapter 3
3.3 Electrical Work

3.3 Electrical Work
Learning Outcomes:
• Explain the definition of current, voltage and resistant
• Explain four electrical hazards
• Plan two basic preventive steps related to electrical safety
• Classify at least four factors that are normally considered in safe
electrical usage
• Relate legal provision related to electrical safety
3.3 Electrical Work
Electric
• A type of energy. An efficient and easily available energy
• Usage: Lighting, heating, energy application (oven, furnace etc.)
Terminology:
• Electric is an energy resulted from conduction of electrons. It is a
general term which includes the energy related to electric charges
whether static or dynamic
• Factors influencing electrical energy:

▫ Voltage (Volt) : A representation of electrical potential energy
▫ Current (Ampere): Represents the flow of electrons through a
conductive material
▫ Resistant (Ohm) : The characteristic of a circuit or path in which
electric flows and the path offer a resistance to the flow
3.3 Electrical Work
• The advantages of electrical energy

▫ Cheap
▫ Clean
▫ Easy to use
▫ No storage is required
• The characteristics of electrical energy

▫ It cannot be seen
▫ It cannot be heard
▫ It cannot be smelled
3.3 Electrical Work
• The electrical installation includes:

▫ Electric circuit
▫ Conductors
▫ Main switches, local switches and distributing board
▫ Circuit breakers
▫ Fuses
▫ Socket and plug
• The electric circuits are:

▫ The path where the electric current flows
▫ It provides the source of electrical energy
▫ It includes the conductors to enable the current to be controlled
3.3 Electrical Work
• The conductors:
▫ Includes metal component that allows the conductions of
electricity at the center part and insulation material (rubber) at
the outer part.
• Main switches, local switches and distributing board

▫ Main switches function to receive electric current from the
electricity source and distribute it to other areas that need it.
▫ Main switches and local switches also functions to stop the flow
of electric current in a circuit.
▫ Distributing board provides a location for the main switches,
circuit breakers and other related switches. It receives electric
current from the external source before distributing it to other
area.
• circuit breakers: 3.3 Electrical Work

▫ Function when there are excess electricity load
▫ To prevent excess heat that can cause fire
▫ In the form of closed switch
▫ It has a mechanism to release the switch from ‘on’ position to ‘off’
position if excess current flows through the circuit
• Fuses
▫ A piece of thin metal that melts at the current value below the excessive
current flow
▫ It stops the electricity supply
• Output socket and plug

▫ Output socket enters a circuit when tapping is performed and it allows
electrical energy to be supplied to equipment
▫ Plug is connected to the flexible cable supplying electrical energy to
equipment. It is inserted into the output socket and hence establishing
another circuit
3.3 Electrical Work
The effect of electrical hazards

• Electric shock
• Excessive brightness
• Fire
• Static electricity
• Electric shock
▫ Normally from life wire to earth wire
▫ Causing muscular contraction shortened and thickening (cramp
or spasm)
▫ Can disturb the normal heart response
▫ Can cause breathing failure
3.3 Electrical Work
• Excessive brightness (from arc eyes)

▫ From ultra violet rays when looking at the electrical ark or the
welding light.
▫ Symptom like conjunctivitis
▫ Temporary symptom will continue for 3 or 4 days
▫ It makes the contact lens not effective
• Fire
▫ It is caused by the contact of electrical arc resulted from
conductor short circuit or excessive equipment electrical load
▫ Or the release of static electric charge
3.3 Electrical Work
• Static Electricity
▫ It is the effect of trapped electric charge in the insulator. This
charge can be distributed to either inside or outside of the
insulated object. Or it can be concentrated on a conductor which
is insulated from the earth.
▫ High voltage, low current
▫ Can result to electric shock and igniting source within flamable

environment (if the static charge is high)
Electrical Safety 3.3 Electrical Work
The effect of electric current

varies depending on:
▫ Age
▫ Sex
▫ Body electrical resistance
▫ Health condition FLOWS OF ELECTRIC CURRENT
▫ The amount of flowing THROUGH BODY
Major pain
current and its voltage Medium pain
▫ The seriousness of the electric

shock
▫ The total time of the current
flow To earth To earth
Hand to Leg Hand to Hand

Copyright@NIOSH 2004/2
3.3 Electrical Work
OHMs Law
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 ( 𝑉 )
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 ( 𝐼 ) =
𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 ( 𝑅 )
Or using the measurement unit:

𝑉𝑜𝑙𝑡
𝐴𝑚𝑝𝑒𝑟𝑒 =
𝑂ℎ𝑚
Example:
For measuring the effect of electric shock.
Voltage = 240 volt
Average body resistance = 100 ohm
𝑉𝑜𝑙𝑡 240
𝐴𝑚𝑝𝑒𝑟𝑒 = = = 2.4 𝑎𝑚𝑝𝑠
𝑂ℎ𝑚 100
3.3 Electrical Work
The effect of electricity contact to human

Electric current Effect to human
3 milliamps Mild shock
7 milliamps Painful electric shock
20 milliamps Difficult to breath
70 milliamps Death risk
700 milliamps Body tissue burnt
3000 milliamps Heart failure
3.3 Electrical Work
Human body resistance towards electric current

Type of resistance Resistance value
Dry human skin 100,000 – 600,000 ohms
Wet human skin Estimated 1,000 ohms
Internal human body (Hand to leg) 400 – 800 ohms
Ear to ear Estimated 100 ohms
3.3 Electrical Work
Estimated threshold shocking voltage at 50 hz

Threshold for able to feel minimum shock 10 – 12 volt
Threshold to feel painful shock 15 volt
Threshold to feel very painful shock 20 volt
Threshold that result to hand fisting 20 – 25 volt
Threshold that result to vibrated body 50/60 – 2000 volt
3.3 Electrical Work
Principles of Electrical Safety
• The main objective is to protect human from electric shock, fire and
burning effect resulted from contact with electricity
• Two fundamental preventive steps are:

▫ Prevention from direct contact with electricity
▫ Prevention from indirect contact with electricity
• Prevention from direct contact with electricity

▫ Provides insulator to parts of equipment that has potential to
release electric charge
• Prevention from indirect contact with electricity

▫ Provides effective earthing to isolate metals that could discharge
electricity if main insulation fails.
3.3 Electrical Work
Safe electricity usage

• Factors to consider:
▫ Circuit protection
▫ Isolation switches
▫ Maintenance and repair of damaged equipments
▫ Earthing
▫ Protection
• Circuit protection
▫ All electrical equipments must be equipped with
appropriate fuses and circuit breakers to prevent
excessive loads.
3.3 Electrical Work
• Isolation switches
▫ All isolation switches must be labeled
▫ Must be easily assessable at the working floor
▫ Must be installed at each individual machine
▫ Equipped with locking facility when it is ‘off’ position
• Maintenance and repair of damaged equipments

▫ Establish safe work system during maintenance
▫ Establish related rules and inspection/monitoring
▫ Establish maintenance program/schedule
▫ Provides access area surrounding the equipments for
maintenance and repair purposes
▫ Executed by certified/competent electrician
▫ Replacement of components such as fuses or capacitor must be of
appropriate and correct type.
3.3 Electrical Work
• Earthing
▫ Must be provided for all electrical equipments
▫ Earth circuit must be directly connected to earth (not going
through switches)
• Protection
▫ Provide earth leakage protection such as Residual Current
Devices.
▫ Provide emergency stop switch and interlock switch (example:
limit switches)
▫ Insulate conductors
▫ Installation of safety signboards.
3.3 Electrical Work
Electrical safety controls
• Establishing laws, rules and enforcement by the

government
▫ Electricity Supply Act 1990
▫ Electricity Supply Regulations 1994
▫ SIRIM standards
▫ Occupational Safety and Health Act 1994 (OSHA
1994):
3.3 Electrical Work
Electrical safety controls
• Employers’ responsibility:
 Establish Safe Work System
 Provide training, information and instruction
 Establish preventive and protective action plan for employees
and contractors.
• Equipment manufacturer, supplier and

designer:
 Establish testing and inspection to ensure users safety
• Employees’ responsibility:
▫ Follow the rules established by the employer.
3.3 Electrical Work
Class Activities
1. Explain the definition of current, voltage and
resistant.
2. Explain four electrical hazards.
3. Plan two basic preventive steps related to
electrical safety.
4. Classify at least four factors that are normally
considered in safe electrical usage.
5. Relate legal provision related to electrical
safety.
3.3 Electrical Work
Conclusions
• Electricity has many hazards that can affect the
employees’ safety and health.
• There are two fundamental preventive steps that
can be taken to protect human from electrical
hazards.
• This is followed by executing safe electricity
usage discussed in the section.
• The government also controls the safe electricity
usage by establishing several act and
regulations.
Chapter 3
3.4 Mechanical Work

3.4 Mechanical Work
Learning Outcomes:
• Summarize the legislative requirements related to mechanical
handling.
• Explain the definition of mechanical handling
• Explain five types of mechanical handling.
• Compare the advantages and disadvantages of mechanical handling.
• Summarize four important components of mechanical equipment.
• Classify mechanical hazards related to lift, conveyor, forklift, crane
and escalator.
• Plan safety action plan for mechanical handling.
• Plan the hazards preventive and control steps for mechanical
handling.
• Explain five types and causes of mechanical handling weaknesses.
Legal Requirements 3.4 Mechanical Work

• Occupational Safety and Health Act 1994
▫ General Duties of Employers and self employed person:
Section 15 (2) (b)
▫ To ensure as far as is practicable the safety and no risk to the
health related to the usage or handling, storage and
transportation of plant and substance
▫ General Duties of a person who designs, manufactures, imports,

or supply: Section 20
▫ To ensure that there is adequate research and test on the
substance / plant for the purpose of customers / users safety.
▫ General Duties of an employee: Section 24(d)

▫ To comply with any instruction on safety and health given or
issued by the employer or any other person having the authority
to give such instruction.
3.4 Mechanical Work
• Legislative Requirements
• Factory and Machinery Act 1967
▫ Regulations on factory and machinery (Electrical
lift for passengers and goods):
 Conditions:
 Design approval
 Inspection, load test, and operation test.
 Registration and issuance of Certificate of Fitness (if pass the
test)
Hoisting machinery that requires certificate of fitness 3.4 Mechanical Work
 Lift  Passenger Hoist
 Passenger  Material Hoist
 Goods  Skip Hoist
 Dumbwaiter  Goods hoist
 Gondola
 Escalator  Electric chain Hoist

 Walkalator  Pneumatic Hoist
 Travellator
 Truck mounted  Mobile Crane

Crane  Crawler Crane
 Tower Crane
 Overhead traveling  Sky lifter

crane  Cherry picker
 Gantry Crane  Two & Four post lift
 Portal Crane  Table Lifter
 Container Crane  Mechanical car parking
3.4 Mechanical Work
Definition: Usage of any powered equipment (hydraulic, pneumatic,
electric or mechanical) for the purpose of:
▫ Moving
▫ Lifting
▫ Relocate
▫ Remove
• load / goods inclusive of human
Type of equipments are:

• Lift ,dumbwaiter
• Escalator, travellator, walkalator
• Crane and hoist
• Conveyor
• Forklift
3.4 Mechanical Work
3.4 Mechanical Work
3.4 Mechanical Work
Mechanical Handling Equipment
• Why mechanical handling is required?
• Heavy load
▫ Large size / very large load
• Variations in loads shape
• To speed up the work process
• Advantages of mechanical handling?

▫ Ease the task / job
▫ Speed up the work
▫ Reduce ergonomic risk to the employee
▫ The equipment can reach the ‘difficult to reach’ area
▫ Increase the productivity
▫ Save storage space because material can be arranged in vertical
direction.
3.4 Mechanical Work
Disadvantages of mechanical handling
▫ Requires competent operator (crane, forklift)
▫ Some mechanical handling equipment requires Certificate of
Fitness
▫ Equipments need maintenance
▫ Increase of initial cost
▫ Equipment can increase the risk related to safety and health
• Major components of mechanical equipments

▫ Wire rope
▫ Chain
▫ Lifting motor
▫ Counterweight
▫ Lifting Tackle (which consists of):
 Sling, hook, grip, Eyebolts, spreader bar and Shackle
3.4 Mechanical Work
3.4 Mechanical Work
Hazards of mechanical handling equipments
3.4 Mechanical Work

MACHINES HAZARDS
 Lift (For maintenance employee)

 Caught between lift and shaft wall
 In contact with rotating parts
 Fall from lift roof
 Ergonomic related problems
 Electric shock
 Conveyor  Caught between rollers

 In contact with rotating parts
 Truck  Getting hit by equipment

 Fork lift  Hit by fallen load from the equipment
 Caught between equipment and object
 Crawler crane  Hit by equipment

 Mobile crane  Caught between load and equipment
 Tower crane  Hit by fallen load from the equipment
 Overhead
travelling crane
 Escalator For passengers

 Caught between moving parts
 Fall
For maintenance employees
 Caught between rollers or chain
 Ergonomic related problems
 Electric shock
3.4 Mechanical Work
Source of Hazards: Types of frequently occurred defects
• Wire rope size decreases
• The length of wire rope or chain increases
• Eroded chain surface
• Eroded lifting equipment
• Loose hooks
• Malfunction of braking system
• Broken wire rope
• Bending girder structure
• Bending boom
• Malfunction of limit switch system
• Safety latch for hook is not in place
3.4 Mechanical Work
Causes of defects
▫ No maintenance
▫ Over loaded
▫ Error in design of equipment and structure
▫ Environmental factors
▫ Tools used do not comply to the standards
▫ No periodical inspection
3.4 Mechanical Work
Types of accident
• Caught between objects
• Fallen objects from elevated area
• Lifting machine tipped off
• Boom / crane structure broken / fall down
• Hit by object
• Fallen of load from lifting machine
• Electric shock
3.4 Mechanical Work
• Caught between objects
▫ Example: While executing the task of lifting a load or maintaining
the wire rope mechanism / chained equipment
▫ Causing factors:
 Limited working space
 No fencing
• Fallen objects from elevated area

 Poor housekeeping at working area
 No toe-board at the working platform
 Safety net is not installed
 Unsafe lifting method
 Improper position of hook and sling during lifting
 Mechanical failure
3.4 Mechanical Work
• Lifting machine tipped off
 Error in estimating the weight of load
 Soft soil at the lifting site
 Wrong lifting technique
 Ground condition is not suitable (cliff, not a flat land)
• Boom / crane structure broken / fall down

 The load is over weight
 Damaged boom is used
 Design mistake
 The installation does not follow standard procedure
3.4 Mechanical Work
• Hit by object
 Working environment condition
 Limited working space
 Insufficient lighting
 Slippery floor
 Vehicle mechanical failure (brake system)
 Operators mistake
 The load size is not suitable (big, heavy)
3.4 Mechanical Work
Safety Plan
• Step 1
▫ Identify hazards related to work
▫ Assess the risk of each identified
▫ Arrange preventive and control actions
▫ Monitor the executed actions
3.4 Mechanical Work
• Factors to be considered before and after lifting process
▫ Types of load (solid, liquid or gas)
▫ Weight of the load to be lifted
▫ Size of the load to be lifted
▫ Shape of the load
▫ Type of lifting machine
▫ Condition of the working area for the lifting process
▫ Type of lifting tackle to be used
▫ Operator handling the work
▫ Type of activity to be executed (lifting, removing)
▫ Load stability
▫ Lifting machine capacity
▫ Lifting technique and procedure
▫ Environment conditions
▫ Pathway for the lifting activity
3.4 Mechanical Work
Methods for hazards preventive and control
• Conducting periodical inspection to machinery and its component
• Establish periodical maintenance plan for lifting machines
• Establish safe work procedure for handling activities
• Select appropriate and competent employees
• Provide training to selected employees
• Choose and use safe and suitable handling machines
• Supervise the execution of job
• Fence the working area
• Put warning signboard (to warn other employees about the hazard
at the designated area)
• Install safety device at the machines
• Use effective communication system
3.4 Mechanical Work
Class Activities
1. Summarize the legislative requirements related to mechanical
handling.
2. Explain the definition of mechanical handling
3. Explain five types of mechanical handling.
4. Compare the advantages and disadvantages of mechanical
handling.
5. Summarize four important components of mechanical equipment.
6. Classify mechanical hazards related to lift, conveyor, forklift, crane
and escalator.
7. Plan safety action plan for mechanical handling.
8. Plan the hazards preventive and control steps for mechanical
handling.
9. Explain five types and causes of mechanical handling weaknesses.
3.4 Mechanical Work
Conclusions
1. Mechanical handling functions to allow working task be done

easier and faster.
2. There are specific legislative provisions related to mechanical

handling.
3. Mechanical handling hazard can be prevented by establishing

safety planning before and at the time of executing the handling
activities.
3.5 Chemical Work
Joe Nail
82
Industrial Safety Lecture Three 12/4/2018
3.5 Chemical Work
Introduction
 What is a Chemical Hazard?
– Answer: Any chemical that can cause illness,

injury, or an emergency.
 Chemical Hazards
– Physical
– Health
83
3.5 Chemical Work
Chemical Hazards
84
3.5 Chemical Work
Chemical Hazards
 Pyrophoric
 Flammable Chemicals
 Combustible Chemicals
 Oxidizers
85
3.5 Chemical Work
OHSA’s Haz-Com Standard

OSHA’s Hazard Communication Standard is designed to protect
employees from hazardous chemicals used or stored in the work
setting.
Also referred to as the "Right-To-Know Law" Law, the Hazard
Communication Standard requires that information and
training (i.e., hazcom training) be provided to any employees
who have the potential of being exposed to a hazardous chemical
“under normal condition of use or in a foreseeable emergency.”
Such hazcom training requires the presence of hazardous
chemicals be communicated to employees in a variety of ways,
including:
86
3.5 Chemical Work
Purpose
 The purpose of the
standard is to make sure
that the hazards of
chemicals are evaluated
 That information
concerning their hazards is
communicated to
employers and employees
3.5 Chemical Work
Who is covered
 OSHA’s Hazard Communication
(HazCom) standard applies to general
industry, shipyard, marine terminals,
longshoring, and construction
employment and covers chemical
manufacturers, importers, employers,
and employees exposed to chemical
hazards. Horizontal
3.5 Chemical Work
HazCom Requirements
 The hazardous chemical inventory
 Material Safety Data Sheets (MSDSs)
 Labels, tags or signs
 The written Hazard Communication
program
89
3.5 Chemical Work
Background
 The Hazard Communication Standard (HCS)
is based on a simple concept--that employees
have both a need and a right to know the
hazards and identities of the chemicals they
are exposed to when working
3.5 Chemical Work
3.5 Chemical Work
Background
 They also need to know what protective
measures are available to prevent adverse
effects from occurring
 The HCS is designed to provide employees
with the information they need
MSDS
3.5 Chemical Work
Employers
 Employers are required to provide information
to their employees about the hazardous
chemicals to which they are exposed using:
– A hazard communication program
– labels and other forms of warnings
– material safety data sheets (MSDS)
– information and training
3.5 Chemical Work
Warehouse and Retail Operations
 In work operations where employees only handle chemicals

in sealed containers, which are not opened under normal
conditions
 Employers must only do the following:
– Ensure labels on incoming chemicals are not
defaced or removed
– Maintain copies of any material safety data sheets that
are received with incoming shipments
– Obtain MSDS a.s.a.p. for shipments received w/out
MSDS
Warehouse and Retail Operations
 Provide employees with information and
training (no written program required) to the
extent necessary to protect them in the event
of a spill or leak of a hazardous chemical from
a sealed container
3.5 Chemical Work

3.5 Chemical Work
Labeling Exemptions
 Other federal agencies control the labeling
requirements for the following substances:
– Pesticides
– Chemicals covered under the Toxic Substance
Control Act
– Foods or food additives
– Distilled Spirits, tobacco
– Consumer products, lumber, cosmetics
– Hazardous wastes
Employer Requirements-
Written Program
 Employers must develop a written program
that covers at least:
– Labels and other forms of warnings
– Material Safety Data Sheets
– Employee Information and Training
3.5 Chemical Work

Employer Requirements-
Written Program
 Employers must develop a written program
that covers at least:
– A list of the hazardous chemicals known to be
present at the facility along with MSDS’s for each
chemical
– The methods the employer
will use to inform employees
of the hazards non-routine tasks
– The hazards of chemicals
in unlabeled pipes 3.5 Chemical Work
3.5 Chemical Work
Multi-Employer Workplaces
 If employees of other employers could be
exposed to hazardous chemicals the program
must include:
– Methods to provide contractor employees with on-
site access to MSDS for each chemical those
workers may be exposed to
– The methods used to inform other employers of
any precautionary measures to be taken for
normal and emergency situations
– The employers chemical labeling system
3.5 Chemical Work
Consumer Products Exemption
 Any consumer product as defined in the
Consumer Product Safety Act where the
employer can show that:
– It is used in the workplace for the purpose
intended
– The use results in a duration and frequency of
exposure which is not greater than the range of
exposures that could reasonably be experienced
by consumers when used for the purpose intended
3.5 Chemical Work
Written Program Availability

 The employer must make the written program
available, upon request, to:
– Employees and their designated representatives
 Where work is carried out at more than one

location, the program may be kept at the main
location
Labels, Tags and Markings
 The employer must ensure that each
container of hazardous chemicals in the
workplace is labeled, tagged or marked with
the following:
– Identity of the hazardous chemical
– Appropriate hazard warnings
 This above labeling information is required of
the manufacturer so the employer must
ensure that the original labels from the
manufacturer are on all containers and
remain legible 3.5 Chemical Work
Container Labeling Exemption for
Portable Containers 3.5 Chemical Work
 The employer is not required to label portable

containers into which hazardous chemicals are
transferred from labeled containers, and which
are intended only for the immediate use by
the employee who performs the transfer
3.5 Chemical Work
The employer need not
affix new labels to comply
with the standard if
existing labels already covey
the required information
3.5 Chemical Work
New Hazard Information

 Manufacturers, importers,
distributors and employers
who become newly aware of
significant information
regarding chemical hazards
shall:
– Revise the labels for the
chemical within three months
– Revise the MSDS for the
chemical within three months
3.5 Chemical Work
MSDS kept in other forms

 MSDS may be kept in any form including
operating procedures
 It may be more appropriate to address the
hazards of a process rather than individual
hazardous chemicals
Employee Information and
Training 3.5 Chemical Work
 Employers must provide employees

information and training on hazardous
chemicals in their work area:
– At the time of their initial assignment
– Whenever a new physical or health hazard
the employees have not previously been
trained about is introduced into their work
area
 Training may cover categories of hazards
3.5 Chemical Work
Employee Information
 Employers must inform employees:
– Of the training requirements of this section
(1910.1200 (h) Employee information and
training.);
– Any operations in their work area where
hazardous chemicals are present;
– The location and availability of the written hazard
communication program
3.5 Chemical Work
Employee Training
 Employee training shall include at least:
– The means to detect the presence or release of a
hazardous chemical in the work area
– The physical and health hazards of chemicals in
the work area
– Measures employees can take to protect
themselves
– Details of the employers specific program
3.5 Chemical Work
Health Hazards
 Category A-Biological Agents
 Category B-Physical Agents
 Category C-Chemical Agents
 Chemical Agents-This Discussion
110
3.5 Chemical Work
Chemical Health Effects
 Irritants: Inflame skin tissue on contact.

 Corrosives: Destroy skin tissue at point of
contact.
 Sensitizers: Cause allergic reactions.
 Target-Organ Chemicals: Damage specific
body organs and systems.
 Reproductive Hazards: Change genetic
information in egg or sperm cells and/or
damage fetus after conception.
 Carcinogens: Cause cancer.
111
3.5 Chemical Work
Health Hazards
 Sensitizers
 Target-Organ Chemicals
 Reproductive Hazards
 Carcinogens
112
3.5 Chemical Work
Health Hazards
 Irritants
 Corrosives
113
3.5 Chemical Work
Corrosive
 Visible destruction, or irreversible damage to
body tissue
 Acids
 Caustics (or bases)
Caustics
Acids pH Scale (or bases)
1 7 14
3.5 Chemical Work
3.5 Chemical Work
Hepatotoxins
 Chemicals which produce liver damage
 Signs and Symptoms: Jaundice, liver
enlargement
 Chemicals: Carbon Tetrachloride,
nitrosamines
3.5 Chemical Work
Nephrotoxins
 Chemicals which
produce kidney damage
 Signs and Symptoms:
Edema
 Chemicals: Halogenated
Hydrocarbons, uranium
3.5 Chemical Work
Neurotoxins
 Chemicals which produce
their primary toxic effects on
the nervous system
Narcosis, behavioral
changes, decreased motor
function
 Chemicals: Mercury, carbon
disulfide, lead
3.5 Chemical Work
Agents which act on the blood
 Decrease hemoglobin
function, deprive the
body tissues of oxygen
Cyanosis, loss of
consciousness
 Chemicals: Carbon
monoxide, cyanides
3.5 Chemical Work
Agents which damage the lungs
 Chemicals which
damage pulmonary
tissue
Cough, tightness in
the chest, loss of
breath
 Chemicals: Asbestos,
3.5 Chemical Work
Reproductive toxins
 Chemicals which damage
reproductive capabilities
 Includes chromosomal
damage (mutations) and
damage to fetuses
(teratogenesis)
Birth defects, sterility
 Chemicals: Lead
3.5 Chemical Work
Cutaneous hazards
 Chemicals which effect
the dermal layer of the
body
Defatting of the skin,
rashes, irritation
 Chemicals: Ketones,
chlorinated compounds
3.5 Chemical Work
Eye hazards
 Chemicals which affect the eye or visual
capacity
 Signs and symptoms: Conjunctivitis,
corneal damage, blurred vision, burning or
irritation
 Chemicals: Solvents, corrosives
3.5 Chemical Work
Material Safety Data Sheets (MSDS)

are one of the most important tools
available to employers
for providing information, and protection
to workers from hazardous chemicals
which are used in the workplace.
1910.1200 (g)(2) MSDS, 3.5 Chemical Work
required information
 Identity of the chemical  Whether the hazardous
 Physical and chemical chemical is listed in the
characteristics National Toxicology
 Physical hazards Program (NTP) Annual
Report on Carcinogens
 Chemical hazards
 precautions for safe
 Primary routes of entry
handling and use
 PEL’s or other
 Date of preparation
exposure limits
 Name, address and
 Control measures
telephone of the
 Emergency procedures manufacturer
Material Safety Data Sheet U.S. Department of Labor 3.5 Chemical Work
May be used to comply with Occupational Safety and Health Administration
OSHA's Hazard Communication Standard, (Non-Mandatory Form)
29 CFR 1910.1200. Standard must be consulted for specific requirements.
Form Approved
OMB No. 1218-0072
IDENTITY (As Used on Label and List) Note: Blank spaces are not permitted. If
any item is not applicable, or no information is available, the space must be marked to
indicate that.
Section I
Manufacturer's Name Emergency Telephone Number
Address (Number, Street, City, State, and ZIP Code) Telephone Number for
Information
Date Prepared
Signature of Preparer (optional)
3.5 Chemical Work
Section II - Hazard Ingredients/Identity Information
Hazardous Components (Specific Chemical Identity;
Common Name(s)) OSHA PEL ACGIH TLV Other
Limits
Recommended%(optional)
3.5 Chemical Work
Section III - Physical/Chemical Characteristics
Boiling Point Specific Gravity (H2O = 1)
Vapor Pressure (mm Hg.) Melting Point
Vapor Density (AIR = 1) Evaporation Rate

(Butyl Acetate = 1)
Solubility in Water
Appearance and Odor

3.5 Chemical Work
Section IV - Fire and Explosion Hazard Data
Flash Point (Method Used) Flammable Limits LEL
UEL
Extinguishing Media
Special Fire Fighting Procedures
Unusual Fire and Explosion Hazards

Section V - Reactivity Data 3.5 Chemical Work
Stability Unstable Conditions to Avoid
Stable
Incompatibility (Materials to Avoid)
Hazardous Decomposition or Byproducts
Hazardous
Polymerization May Occur Conditions to Avoid
Will Not Occur

Section VI - Health Hazard Data 3.5 Chemical Work
Route(s) of Entry: Inhalation? Skin? Ingestion?
Health Hazards (Acute and Chronic)
Carcinogenicity: NTP? IARC Monographs? OSHA

Regulated?
Signs and Symptoms of Exposure
Medical Conditions
Generally Aggravated by Exposure
Emergency and First Aid Procedures

3.5 Chemical Work
Section VII - Precautions for Safe Handling and Use
Steps to Be Taken in Case Material is Released or Spilled
Waste Disposal Method
Precautions to Be taken in Handling and Storing
Other Precautions
Section VIII - Control Measures 3.5 Chemical Work
Respiratory Protection (Specify Type)
Ventilation Local Exhaust Special
Mechanical (General) Other
Protective Gloves Eye Protection
Other Protective Clothing or Equipment
Work/Hygienic Practices
3.5 Chemical Work
Setting up a program
 The HCS covers both:
– Physical hazards (such as flammability),
and
– Health hazards (such as irritation, lung damage,
and cancer)
 Most chemicals used in the workplace have
some hazard potential, and thus will be
covered by the rule
3.5 Chemical Work
 One difference between this rule and many
others adopted by OSHA is that this one is
performance-oriented
 That means that you have the flexibility to
adapt the rule to the needs of your workplace,
rather than having to follow specific, rigid
requirements
3.5 Chemical Work
 Make a list of all chemicals in the workplace
that are potentially hazardous
 The best way to prepare a comprehensive
list is to survey the workplace
 Identify chemicals in containers, including
pipes
 Establish purchasing procedures so that
MSDSs are being received before a
material is used in the workplace
3.5 Chemical Work
Identify hazardous
chemicals in the workplace.
 Compile a complete list of the potentially
hazardous chemicals in the workplace
 Determine if you have received material
safety data sheets for all of them
 If any are missing, contact your supplier
and request one
 You should not allow employees to use
any chemicals for which you have not
received an MSDS
3.5 Chemical Work
Preparing and implementing a hazard
communication program
 All workplaces where employees

are exposed to hazardous
chemicals must have a written
plan
 The plan does not have to be

lengthy or complicated
3.5 Chemical Work
Employee training
 If there are only a few chemicals in the
workplace, then you may want to discuss each
one individually
 Where there are large numbers of chemicals,
or the chemicals change frequently, you will
probably want to train generally based on the
hazard categories (e.g., flammable liquids,
corrosive materials, carcinogens)
3.5 Chemical Work
Documentation
 The rule does not require
employers to maintain
records of employee
training, but many Hazard
Communication
employers choose to do so
 This may help you monitor
your own program to
ensure that all employees
are appropriately trained
3.5 Chemical Work
Recognizing Chemical Health

Effects-What to Look for.
 Symptoms appear while you are at
work.
 Symptoms get worse during the work
week but go away when you are off.
 Fellow employees have reported similar
symptoms.
141
3.5 Chemical Work
Forms of Chemical Hazards

 Solids, Liquids, Gases, Vapors, Mists,
Dusts, and Fumes.
 Exposure Routes
142
3.5 Chemical Work
Control of Chemical Hazards

and Exposures
 Engineering and Mechanical Controls
 Personal Protective Equipment
 Administrative and Procedural Controls
143
3.5 Chemical Work
Chemical Spill Response

 Requires Special Training
 What can I do?
144
3.5 Chemical Work
Chemical Spill Response

CFR 1910.120 Hazardous Waste Operations and Response Standard
(HAZWOPER)
 Option #1-Evacuate employees and call in

professional emergency response
personnel. (EAP) 29 CFR1010.38(a)
 Option #2-Respond internally. (EAP) 29 CFR

1010.120
145
3.5 Chemical Work
First Aid for Chemical Exposure

 Ingestion
 Inhalation
 Skin Contact
 Eye Contact
 Burns
146
3.5 Chemical Work
Review
 1. Give the names of the two chemical hazards.
 2. What name is given to a chemical which will burst into
flame when contacted by air?
 3. What term is given to chemicals which can cause and
/or support fire in other materials?
 4. What is a health hazard?
 5. Which kind of health hazard destroys skin on contact?
 6. Chemicals that cause sterility, fetal death, and birth
defects are called ____________.
 7. What is a carcinogen?
 8. Give the three states in which a chemical can exist.
 9. Give the three ways employees can be exposed to
health hazards.
 10.What are the most common skin contact hazards?
 11.What is an MSDS?
 12.What kind of information is found on the MSDS? 147
Example of Course Assessments
Q3 (a) Some common factors to be considered in the area of electrical safety

are isolation switches, maintenance or repair of damaged equipments,
and system protection. For each of the listed factors, choose three (3)
strategies or action plans that can be implemented to prevent electrical
related injury.
(9 marks)
(b) Considering you are an engineer responsible for mechanical

handling equipments in a heavy industry environment. Propose six
(6) methods that can be practically applied to prevent and control
mechanical related hazards. Provide clear justification or
explanation for each proposal.
16. marks)
Q3 (a) “Five people were killed on Saturday when a private helicopter crashed in
Kuala Lumpur during installation of final part top of a communication
tower, including the co-pilot and workers of Helistall Sdn. Bhd. The death
comprised all three men on board, a pregnant woman and a child who were
walking along the busy road on which the helicopter crashed”.
Referring to this accident, provide your evaluation and suggestion on:
i. Potential factors that cause the accident.

(6 marks)
ii. Strategies for hazards prevention and control.

(6 marks)
(b) Machineries and equipments in manufacturing industries require proper

handling to ensure safety. Provide your evaluation and suggestion on:
i. Typical accidents related to mechanical handling machineries and

equipments.
(6 marks)
ii. Strategies for accident prevention related to mechanical handling

machineries and equipments.
(7 marks)
Q3 (a) Accidents data at construction sites in 2016 was collected for research purposes.
The data was analysed and categorised into several groups. You have reviewed and
assessed the analysis report based on hazards in Figure Q3(a). You are requested to
summarise the review and assessment findings and justify the FOUR (4) main
factors contributed to each of the above accident categories.
(16 marks)
(b) Electricity has many hazards that can affect the employee safety and health.
Classify and briefly explain THREE (3) factors that are normally considered in
safe electrical usage.
(9 marks)

03 - Physical Injury and Controls 1

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03 - Physical Injury and Controls 1

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OCCUPATIONAL SAFETY AND HEALTH

3.1 Introduction to Physical Injury

• an act that damages or hurts

• Legal definition; an act that wrongs or harms another;

Definition of Physical Injury

• Major trauma is injury that has the potential to cause

[1] Jump up to: a b "Wounds and Injuries: MedlinePlus". Nlm.nih.gov.

Cover physical injury and control

• 3.3 Electrical Work

• 3.4 Mechanical Work

• 3.5 Chemical Work

3.2 Construction Work

Definition of Building Operations (FMA 1967)

Activities at construction sites

Hazards at construction sites

Types of typical accidents:

Falling from elevated area is normally associated

Factors that cause falling from elevated area:

• No wall or fence at working area

Causal factors of getting struck by fallen object:

Drown is normally associated with:

Inhaling toxic chemical

In contact with rotating machine parts or caught between objects

Safety and health management

BDA 31302 Occupational Safety & Health

Safety and Health Management within Employers controls:

Class Activities/ Discussions

• There are established regulations related to safety and

• Employers must manage the safety and health aspects in

3.3 Electrical Work

• Factors influencing electrical energy:

• The advantages of electrical energy

• The characteristics of electrical energy

• The electrical installation includes:

• The electric circuits are:

• Main switches, local switches and distributing board

• circuit breakers: 3.3 Electrical Work

• Output socket and plug

The effect of electrical hazards

• Excessive brightness (from arc eyes)

▫ High voltage, low current

▫ Can result to electric shock and igniting source within flamable

Electrical Safety 3.3 Electrical Work

The effect of electric current

▫ The seriousness of the electric

Hand to Leg Hand to Hand

Or using the measurement unit:

The effect of electricity contact to human

Human body resistance towards electric current

Estimated threshold shocking voltage at 50 hz

• Two fundamental preventive steps are:

• Prevention from direct contact with electricity

• Prevention from indirect contact with electricity

Safe electricity usage

• Maintenance and repair of damaged equipments

• Establishing laws, rules and enforcement by the

• Equipment manufacturer, supplier and

3.4 Mechanical Work

Legal Requirements 3.4 Mechanical Work

▫ General Duties of a person who designs, manufactures, imports,

▫ General Duties of an employee: Section 24(d)

 Escalator  Electric chain Hoist

 Truck mounted  Mobile Crane