Safety Audit During Highway Construction1

Dr. K.N.Jha (knjha@civil.iitd.ac.in)

Department of Civil Engineering

Indian Institute of Technology Delhi

•What did we find?

•Where the audits were conducted?

•How we found the compliance score?

•What are the recommendations?

Contents2

• Structural Safety- emphasis on temporary structures

• Traffic Management and Safety (TS)

• Mechanical/Electrical Machinery/ Fire Safety (ME)

• Construction Safety (CS)

• Worker/Work Zone Safety (WO)

Major Audit Heads3

How accidents are caused due to failure of temporary

structures?4

Collapse of

one floor

leading to

another

View of

collapsed

waffle slab

segment

5

Another view

of collapsed

waffle slab

segment

6

View of the

bent shoring

(due to excess

load)

7

Collapse of

deck slab

between the

two piers

8

Another view

of the

accident site

9

Shoring tower

in position for

the deck slab

adjacent to

the collapsed

slab

10

View of the

portion of the

slab which

failed due to

concrete

overloading

Even the best

formwork

system if not

used properly

can lead to

failure

11

Another view

of the portion

of the slab

which failed

due to

concrete

overloading

(note the

buckled

props)

12

Another view

of the portion

of the slab

which failed

due to

concrete

overloading

13

View of

portion of

slab and

beam

formwork

which

collapsed

14

Another view

of portion of

slab and

beam

formwork

which

collapsed

15

Failure of Launching Girder16

Collapse of

launching

girder in

Laxmi Nagar

Collapse of under construction metro bridge17

View of

Zamrudpur

under

construction

metro bridge

span collapse

Bridge failure during construction18

view of the

accident site

(photo

courtesy

www.chinapos

t.com.tw)

Bridge failure during construction19

Another view

of the

accident site

(photo

courtesy

www.thehindu

businessline.co

m)

Fall of Girder during construction20

View of

dislocated

shutters

Fall of Girder during construction21

Toppled

Girder lying

on ground

Audit Process

Briefing by Audit Team, Contractor’s presentation

Document verification

Comprehensive Field Audit based on check list prepared

for each of the mentioned audit heads

Closure Meeting and Sharing of important findings

Document verification

Sl. No. Description of document

1 Latest Monthly and Quarterly Report

2 All sample formats of (1) Non Compliance Reports;

(2) supervision consultant reports; and (3) RFIs

3 Locations of approved sources of Fine Aggregate;

Coarse Aggregate; and Water along with a map

showing various access/ haul roads

4 Locations of major plants viz Crusher, HMP, WMM

Plant, Batching Plant, etc.

Document verification contd..

5 Locations of camp sites, labour camps &

workshops

6 Locations of Material Stock Yards

7 Ref. Clause 36.6 -Approved Construction

Methodologies for various items of work

8 Temporary Structures/Formwork details of

Individual Contractor

9 EMP - Filled in Information in the prescribed

Formats

Document verification contd..

10 Details of environmental officers of CSC - qualification

and experience

11 Safety Organization chart including names of Contractor

and the details of safety officers of contractor

12 Documentation of Safety Systems adopted by individual

contractor

13 Safety Plan of Contractor

14 Approved Traffic Diversion Plans and Traffic

Management Plans of individual contractors

What did we find?

Shuttering

plates being

used to form

brackets to

support

working

platform

26

What did we find?

Shuttering

plates being

used as

pedestal

(even worse,

they are kept

on loose soil)

27

A view of access to workplace-

misuse of shuttering plateAnother view of access to workplace

A view of bridge formwork-

No trestle is anchoredAnother view of bridge formwork-

Reinforcement is being used as bracing

What did we find?

Foot plates

not in proper

contact with

concrete

pedestals

30

What did we find?

Improper

working

platform, no

hand rails, no

foot guards

31

What did we find?

Erosion of soil

beneath the

shoring was

noticed.

32

A view of wall formwork-

the unsafe scaffolding

A view of bridge formwork-

All safety norms violated

Desired Access and Approach

Makeshift ladder of

inadequate height and unsafe

Unsafe walkway. Inadequate widthwithout hand rails

Single landing mat used for walkway. Landing mat also missing fromAccess tower top to considerablelength and therefore highly unsafe.

Children at elevated locations without PPEs.

No control over the public movement in risky working zone.

Camp: Excavation near weigh bridge

Staging in vicinity of unstable ground

Structural Safety Aspects-Observations

The access to worksite and ladders are scary to say the least.

In majority of the packages, the temporary structures are not designed properly

Consultants instead of checking the drawings wait for the work to get over so that approval formality is avoided.

Wherever the drawings are approved, the implementation is not as per the drawing.

The designs and drawings are not vetted from third party.

Makeshift formwork arrangement with non-standard formwork components are in wide use.

Shutter plates and reinforcements are misused for providing access and diagonal bracings respectively.

Common Good Practices (Temporary Structures Safety)

Package Good Practice

1,2 The formwork is erected on a very well compacted soil.

2 Good bracing arrangement for shoring towers and shore legs

3,4 Good access arrangement

3 Very sturdy foundation for pedestals

3,4 Safety net in use

3,4 Provision of handrails and working platforms

4 Prevention of soil erosion by staking the sand bags around scaffolding bases

Common Bad Practices (Temporary Structures Safety)

Package Bad Practice

1,2,3,4 The access arrangement at some places need improvement

5,7,10,11,12 The erection of formwork was not even complying to the unapproved

drawings. No competent person is employed for inspection.1,2,3,4,5,6,7,8,10,11,12 Proper walk way, Hand rails and working platform was not provided

1,2,3,5,7,8,10,11,12 Formwork components were kept in a loose position and left unattended

1,2,5,8,11,12 The stair case is not properly placed1,5,7,8,10,11,12 Improper or absence usage of safety nets1,2,3,4,5,8,11,12 Soil erosion beneath the sleepers was noted1,2,4,5,6,7,8,10,11,12 Usage of makeshift arrangements for access to heights and for staging

work1,5,7,10,11,12 Side fall protection arrangement was missing1,2,5,8,11,12 The ladder was not having enough extension length beyond landing slab

2,4,5,6,8,10,11,12 Improper barricading and missing of handrails1,2,3,4,5,6,7,8,10,11,12 Improper house keeping

3,4,5,6,7,8,10,11,12 Openings in the working platforms left uncovered

Check list- Document compliance

Ladders are safe and inspected regularly?

Has the scaffolding arrangement designed by competent person?

Has it been checked and approved by competent person?

Whether competent person is employed to inspect the scaffold

condition periodically?

Is experienced and trained person employed for erection and

dismantling of scaffolds?

Is site having a practice of providing suitable and sufficient scaffolds so

that the work could safely be done at a height?

Is there a system of inspecting materials of scaffolds on each occasion

before erection?

Whether the approved design, drawing and specifications available for

the formwork system?

Are lifting tool & tackles tested, inspected and checked before use?

Check list-Field compliance

Extension & straight ladders extend 3’ beyond landing?

Are ladders placed on level ground

Are ladders/stairways/ramps position at an angle of about 1:4

Are ladders/stairways/ramps adequately secured

Are base plates in use

Scaffold in plumbed up (vertical tubes)

Entry restriction into effected area

Are diagonal bracings secured and are checked with missing elements

Are lock pin in place and secured

Is scaffold erected in the firm ground.Proper Soil Condition

Is scaffold free from defective components

Is scaffold tag system in use

Is there safe access to the working platform

Check list continuedIs the width of working platform properly maintained

Is there a provision of anchoring full body harness-lanyards to be tied to life

line

Are openings in working platform kept safely covered/fenced

Area below the workplace barricaded, especially below hot-works.

Workmen provided with bag / box to carry bolt, nuts and hand tools.

Has the arrangement for fastening hand tools made.

Fabricated make shift arrangements are checked for quality and type of

material welding, anchoring etc.

Does work at more than one elevation at the same segment restricted.

Safety nets are in use and maintained clean where height is more than 6m

Covering of gaps in form work and edge protection

Is suitable access and egress provided to the formwork areas

Does the formwork comply to the design and drawings

Does the scaffold comply to the design and drawings

Are the workers provided with all the necessary safety gadgets

Interpretations

Compliances Remarks

Yes 78% 2 (Good) 0%

No 22% 1 (Average) 78%

0 (poor) 22%

Interpretations

Compliances Remarks

Yes 18% 2 (Good) 7

No 82% 1 (Average) 11

NA 0 (Poor) 82

From the documentation audit

From the field audit

AUDIT LOCATIONS

SS

Package 1 8+500

9+000

13+339

15+560

20+423Package 2 57+000

73+200

83+000

84+000Package 3 92+000

118+419

122+975

124+000

126+322

126+875

133+585

SSPackage 4 143+400

157+505

Package 5 177+546

194+393

196+615

200+838Package 6 233+726

241+945

244+200

248+300

SSPackage 7 289.100

310.760

Package 8 324+000

327+890

337+000Package 10 423+000:

SS

Package 11 451+98

6,

443+47

4

453+69

0Package 12 516+035

36 locations

FlyoverUnderpassCulvertMinor BridgeMajor BridgeROB

0

20

40

60

80

100

120

PKG 1 PKG 2 PKG 3 PKG 4 PKG 5 PKG 6 PKG 7 PKG 8 PKG 10 PKG 11 PKG 12

% C

om

pliance

s

Package No.

Temporary Structures Safety

Document Compliances Field Compliances

Compliances Comparison

Recommendations-Temporary Structures safety (SS)

Scaffolding

materials

Standard built up frames are

not used and the contractor

uses makeshift arrangement.

The contractor shall use standard

built up frames for scaffolding.

Access arrangement Access arrangement is poor at

nearly all the locations. As

almost everywhere. These

were found to be made of

substandard , make shift type

and unsafe

The formwork design should show

the access arrangement. They

must be well designed and to

provide ramp, walkway, access

and approach at the work

locations

Formwork design

and drawings

No vetting by third party. In

some cases it is approved by

consultants.

The formwork design and

drawings must be vetted by third

party. A certificate to this effect

must be available for inspection

by the CSC and a copy send to

Employer.

Photograph courtesy-Formwork for concrete structures-Tata McGraw Hill

Photograph courtesy- Formwork for concrete structures- Tata Mc Graw Hill

Photograph courtesy- Formwork for concrete structures-Tata Mc Graw Hill

Photograph courtesy-Formwork for concrete structures -Tata Mc Graw Hill

Photograph courtesy- Formwork for concrete structures, in press Tata Mc Graw Hill

Photograph courtesy- Formwork for concrete structures, in press Tata Mc Graw Hill

Photograph courtesy- Formwork for concrete structures-Tata Mc Graw Hill

Traffic Safety findings:

• Documentation compliance in most of the packages is good

• However, the field compliance needs lot more be done

• Traffic diversions and related documentation is prepared generally in compliance with IRC: SP-55: 2001 and IRC:67-2001

• However, ground implementation needs much more to be done than compliance with these guidelines, i.e., they need to be revised

• Traffic control is only passive with no enforcement

Some field views

a) Barricades not there fully at the minor

bridge approaches

b) non standard signages

a) Poor barricading of work space, no

markings

b) Confusing signage at the crossing road; traffic

signal signage although there is none

Accidents and record keeping

Accident data record is kept as required by the NHAI, however, it is not used to improve or modify safety and traffic management on the field

Present accident records are not being used for analysis of risk factors. The details collected, in any case, do not provide information that would be of help in analysis.

The procedure for data collection and format for the same needs to be revised.

This can lead to some actionable points based on the accident trends

Traffic management plans

Very often work starts before the final approval of traffic diversion plans

The field staff understanding is that "work cannot be kept pending for minor changes and finalisation of the traffic plans"

Bridge/flyover construction safety, particularly when there is a road crossing needs special attention –these are potential traffic hazard zones

How is the good compliance going to help

in improving the road safety?

Almost nothing, yes, this is true!!

The best packages which are following traffic

diversions plans, and the worst packages where site

specific plans are not prepared there is a very small

difference in accident rates (according to the records

maintained by the site office of the respective

package)!

This also means that there needs to be an active

traffic control, where the speeds can be reduced

Good and bad practices

Good practices:

Overall Good compliance in documentation and

Flag men presence at diversions

Presence of most signages

Bad practices:

Poor barricading

Non-standard signages

Drop in levels between existing and new carraigeways

Mechanical/electrical/P&M/Fire Safety Findings

Plant and Machinery Inspection, Fitness and Third party Inspections( available in few packages only

Work Permit for Cleaning of Batching Plant Mixing Drums available in very few Packages

Work Permit for maintenance of Hot Mix Plant available in very few Packages

Most of DG sets located in projects fitted with acoustic enclosures

Electrical Safety is poor ( non availability of earthing, use of single insulated cables, non availability of RCCBs, non use of Lugs

Safety aspects of Gas cutting( non use of flash back arrestors/ non return valves, use of domestic gas cylinders and storage of cylinders)

Welding safety procedures( non availability of lugs, improper return earth, non availability of control switches and use of welding generators)

Reverse Horns to machinery absent in most machinery.

Open fuse box. Unsafe wiring. No display of Danger signs. No suitable protection of the surroundings. Cut out used with thick wire which is unsafe

Electrical connection in haphazard way

Cutting operation in adjacent to Oxygen cylinders

Welding machine without fitness sticker. Unsafe wiring/connection

Construction Safety Findings

Work was stopped at most of the locations during audit

Most of the work areas are not barricaded properly

Construction methodology is not prepared scientifically and risks are not analysed.

Work is not planned systematically and mostly done in a haphazard manner.

Tool box talk and worker induction system available in only few packages

a child labor engaged at height without PPEs and supervision

Child labour engaged as a helper.

Dumper No. MP53HA-582.

No reverse horn

Operator: Mr Prithvi without

Driving licence.

Handling/lifting of gas cylinders in unsafe manner instead of using a cradle.

Lack of Side protection by suitable

fence permits unsafe condition

Children at the edge of excavation. No fence. No display of caution signs

A worker in slipper and another bare foot.

Ch 319.60

Children within fencing area Gas cylinders lying on the ground

and over the welding cables.

Children at elevated locations without PPEs.

No control over the

public

movement in risky

working zone.

Camp: Excavation near weigh bridge

Staging in vicinity of

unstable ground

Worker/work zone safety Findings Overemphasis on "visible" worker protection (helmets, jackets,

but not boots, goggles, safety belts) and not enough attention to "safe" work (operating procedures, inspections, safety committees, guards)

Generally poor housekeeping (check-lists, storage, emergency arrangements) and risk measures (fire extinguishers, informatory signs, escape routes)

No regular health monitoring of workers, incomplete medical records, and no analysis of records.

Appalling living conditions, with poor water supply, and little sanitation - much of this is related to the absence of a regular permanent workforce.

Qualified Staff are unavailable for monitoring of Safety and Health Requirements

Material safety Data Sheets and Facilities are not

readily available

Records of treatments and analysis of medical casesare not maintained

Poor welfare facilities at site( toilets at work places , availability of drinking water and rest sheds)

First Aid boxes( non availability and presence of few contents in the First aid boxes)

Open sewage drain

overflowing from the tank

First aid box

at the work site

No date of inspection

mentioned

in drinking water tank)

A view of shelter for

workers

Poor Housekeeping

Lack of dust control

measures

(water sprinkling)

Complete disregard of PPE’s by senior people

Thanks