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0 ABSTRACT
This report is based on a workplace that is taken in a fabrication yard. This report is done
based on the methodology of Hazard Identification, Risk Assessment and Risk Control
(HIRARC) method. The organization chart of the workplace together with the activities or
processes, tasks and safety and health implications are attached together in this report. This
workplace that has been chosen concentrates on fabrication of oil & gas structural materials that
includes many departments including production, project management team, engineering, and
human resource department.
The objective of this report is to identify the main safety and health hazards associated to
the scaffolding activity. The hazards that are identified are evaluated are risk rated by evaluating
the probability and severity using the risk matrix. The qualitative and quantitative data is also
included in this report. Upon risk rating the risks are prioritized and control measures are
discussed. The control measures that are suggested follow the hierarchy of control which is the
elimination, isolation, engineering control, administration control and finally personal protective
equipment (PPE). The relevance of the control measures by recommending several document
review programs are also mentioned and discussed in this report. In a nutshell, the discussion
mentions on the results of the finding, control measures that should be implemented and
recommendations to mitigate or reduce the risk associated to the workplace.
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2.0 INTRODUCTION
China Construction is Chinas largest construction and real estate conglomerate and
biggest building work contractor. It is the largest transnational construction company in the
developing countries and the top home builder in the world, taking the long lead of Chinas
international contracting business. China Construction is well known in the world for
undertaking super high-rise, grand scale, cutting-edge and novel projects and has built up a great
China Construction is one of the most integrated construction and real estate
conglomerates in China with the longest history of specialized operation and market-oriented
management. It is the only construction enterprise in China certified for 3 top grade
Qualifications of general contracting for building works, municipal public works and highway
works, in addition to 1+4 qualifications and first-grade qualification for engineering design of
building industry.
(b) Infrastructure
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The construction that is concentrated for this report is the building work specializing in
super high-rise structure building and steel structure. The project is located at Tun Razak
Construction and Real Estate Conglomerate the eyes of our customers, shareholders and most
The selected project for workplace assignment is the complete project of Exchange 106
that awarded in December 2015, where the total contract price exceeds RM 950 million to
fabricate the additional module on the existing oil platforms off the coast of Terengganu. Layang
serves to compress the oil pressure in the bottom of the sea due to the existing pressure is
The project is owned by TRX and the first piling was on December 2015. The major
construction process takes place at the open area of Sector 1 while some minor assembly takes
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2.2 Organizational Chart
China state construction engineering project has a total workforce of 1500 workers
which includes contractors manpower. The overall organization chart is shown in Figure 1.
The project HSE Committee Member is formed according to the Occupational Safety and
Health (Safety & Health Committee) Regulations 1996 which consists of a chairman, secretary,
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management representatives and worker representatives. The committee meeting is held on
monthly basis. Refer to Figure 2 for the project HSE Committee Organization Chart.
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2.3 Activities and Work Process
In general, China state engineering has a lot of activities that are incorporated in the
construction process. The construction process that is involved are periodically analyzed by
executed at site. The activities that are fundamental for this construction site is as follows:
(d) Scaffolding
For this report, the workplace that is chosen is the scaffolding activity. Scaffolding
activity is executed at many areas including the workshops and open area. This activity is very
important as scaffolds provide a stable platform to work when the structure is built to a certain
height. The scaffolding practices that are adhered are in accordance to the Factory and
Machinery Act 1967 and OSHA 1994. The materials that are used for this scaffolding process
are also complying with British Standards B.S.5973: 1990 code of practices. Additional revised
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B.S. 2052 - Specification for Ropes
There are different types of scaffolding, but usually they are all made up of the same
basic components: tubes and boards. In so-called tube-and-clamp system tubes are attached to
each other by special couplers. Fabricated frame system provides the ready-made frames, which
only need to be braced to ensure the rigidness of the whole system and is commonly in use. This
activity is generally carried out by competent personnel and they are responsible for a safe
erection and dismantling of scaffolds. The scaffolds should be periodically inspected and
maintained to ensure the structure is stable and strong for a long time. In order to start this
process, a proper permit should be applied for either installing or dismantling the scaffolds.
Competent personnel who are registered under Department of Occupational Safety and Health
(DOSH) are responsible to check and verify the scaffold materials and structure. The work
process is briefly described in Appendix 1. A scaffold tags will be in place for every access and
egress. Besides that, the tag will notify the user whether the platform is safe to be used or not.
The structure should be inspected every 7 days or if there are any change in whether
conditions (raining, thunderstorm, strong wing and many more). Employees / workers are only
allowed to start working if green tag is displayed and verified by scaffold inspector. Prior to start
working, a permit should be applied and the control measures as spelled out in the permit should
Any individual who are working at a height more than 2 meters is mandatory to wear
safety harness and when possess a potential of falling from height, they should hook it above and
start working. No obstruction at the access and egress should be in place to ensure evacuation
process goes smoothly in case of any emergencies. All the measures are controlled by the permit
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and a delegated safety supervisor is assigned at site to ensure it is executed safely. A toolbox
meeting should be given to the fellow workers on work related issues and the safe use of
platforms with the measures that should be taken in case of any emergencies.
There are five main hazards that are namely to involve when an activity is involved
which are the physical, chemical, biological, and psychosocial and ergonomics. For this report,
there are many hazards that are identified such as slip, trip and fall, falling object, falling from
height, protruding scaffold, heat stress, ergonomics, material transporting and many more.
The hazards that are identified and discussed for this report is as follows:
Safety Hazards
(a) Falling objects such as clamps, couplers or other material while erecting the scaffold.
Health Hazards
(a) Ergonomics due to material handling and awkward position while working.
(b) Heat Stress due to the peak temperature during hot season.
The working environment is divided into two categories which are in the workshops or in
the open yard. Both the working environment is classified as moderate. The working atmosphere
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for this activity requires permit system, thorough inspections and surveillance, toolbox meetings,
procedure, risk assessments and competent personal to execute the activity safely.
3.0 OBJECTIVES
(a) To identify six safety and health hazards inclusive of 4 safety and 2 health hazards
(b) To access and evaluate the risks that are resulted from each of the hazard;
(c) To prioritize and list these hazards based on their risk rating;
(d) To suggest, list and discuss the control measures to mitigate or reduce the risks;
(e) To recommend document review program for (d) to ensure the effectiveness of managing
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4.0 METHODOLOGY
Conducting Risk there are various ways in identifying the hazards in a work area. The
(a) Reviewing all the Procedures and legal compliance for the workplace
(c) Conducting walkabouts (walk around) at the area and identify the hazards accordingly
(g) Analyzing the UCUA card (You See You Act) reported by management/ workers/
supervisors
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4.2 RISK ASSESSMENT INCLUDING RISK ESTIMATION AND RISK
EVALUATION
Likelihood however is defined as the specified hazardous event happening and severity
Likelihood of the event from happening depends on the control measures, personal
exposure and the unsafe actions and conditions at site. By evaluating all these concerns, a
ranking could be established. The ranking table for the likelihood of occurrence and the
Rating to be used
Likelihood Description
in decision matrix
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Table 1: Likelihood of Occurrence
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4.2.2 Risk Estimation
Risk estimation could be established when the likelihood and the severity of the incident
is multiplied. The estimation of the risk may be distributed in the risk matrix. There are two
types of risk matrix which is the Qualitative and quantitative risk matrix.
Qualitative Risk Matrix (2-D Matrix) Table 3 as below is used to identify the risk of the
hazards.
Severity (S)
1 2 3 4 5
Likelihood (L)
Negligible Minor Moderate Major Catastrophic
5 Most Likely 5 10 15 20 25
4 Possible 4 8 12 16 20
3 Conceivable 3 6 9 12 15
2 Remote 2 4 6 8 10
1 Inconceivable 1 2 3 4 5
Table 3: Qualitative Risk Matrix (2-D Matrix)
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Based on the Qualitative Risk Matrix, the calculated range of risk rating can be
categorized and countermeasure for each category can be visualized as in the Table 4 below:
date of completion.
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4.3 Example of Risk Estimation and Risk Evaluation for The Hazards Identified
Safety hazard
= 3 x 5 = 20 (HIGH)
b) Example 2: Falling objects such as clamps, couplers or other material while erecting the
scaffold.
= 3 x 4 = 12 (MEDIUM)
= 3 X 3 = 9 (MEDIUM)
= 2 X 2 = 2 (LOW)
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Health Hazard
e) Example 5: Ergonomics due to material handling and awkward position while working.
= 4 X 4 = 16 (HIGH)
f) Example 6: Heat Stress due to the peak temperature during hot season
= 3 X 3 = 9 (MEDIUM)
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5 RESULTS AND DISCUSSION
Safety Hazards refer to any force that is strong enough to cause injury or any damage to
property. The hazards can be classified as conditions on which harm to workers is an immediate
and violent and in nature resulting in injury or acute effects. Health Hazards refer to any agent
that can cause illness to an individual. This hazard may produce serious and immediate/ acute
effects, or may cause long term/ chronic problems. All or part of the body may be affected.
There are 4 safety hazards which is fall from height, falling object, slip trip and fall and
finally protruding scaffold. There are also 2 health hazards identified in this report which is
The risk rating that was done using Table 4 has spelled out the possibility of the event to
occur and the severity that can cause an individual. A through studies has been done to it and
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No Hazard Likelihood Severity Risk Evaluation Risk Level
1 Fall from Height 3 5 15 High
2 Falling object 3 4 12 Medium
3 Slip, Trip and Fall 3 3 9 Medium
4 Protruding Scaffold 2 2 4 Low
5 Ergonomics 4 3 12 Medium
6 Heat Stress 3 3 9 Medium
Table 5: Prioritized hazard based on risk rating
The highlighted area in green indicates the critical hazards. The fall from height is the
critical safety hazard that has been identified and the ergonomics is said to be the critical health
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5.3 Impact of The Critical Safety and Health Hazard to The Organization
Fall from height possesses a great risk resulting in fatality if any slight mistake occurs. In
year 2012 statistics, 424,000 died due to fall from height. It has an extensive impact to the
organization in many ways. Since the severity of this hazard results in fatality, loss of life is
experienced by the company loss of life may result in many other losses includes loss to the
production as well. Loss of production occurs when the production phase is stopped and
production phase freezes as investigation will take lead during this interphase. Loss of time
(LTI) will delay the project and this will lead to loss of cost to the organization. Fatality will also
result in loss of cost to bear for the victim especially in his insurance claim and many other
claims which should be paid by the company itself. Further to that, a loss in reputation can be
seen due to the delayed projects and a bad statistic record in the company. This directly will
jeopardize the name of company for future projects in the bidding stage itself.
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5.3.2 Impact of Ergonomics Hazard to The Organization
Ergonomics play a major role in the workers and employees. Ergonomics has a direct
influence to the humans performance which directly results in the beneficiary of the
organizations. If issue pertaining to ergonomics occurs, the comfort of the employee is disturbed.
This will cause a loss in productivity in the employee. This degrading factor in productivity will
result in loss of time and cost for the organization. The human and financial loss also will be
resulted due to the chronic effect of ergonomics. This will lead to higher cost of injuries to the
employees. Increasing injuries to the employee also results in increase number of absenteeism
which also affects the reputation of the company. The potential and performance of the
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6.0 RECOMMENDATION
(a) Elimination
(b) Substitution
(c) Isolation
The two main actions which are the preventive and corrective actions are important to
ensure the correct control measures are taken to mitigate or reduce the safety and health hazards.
The preventive actions that are taken are the permanent actions taken to eliminate the hazards
which concentrates in the elimination and the substitution part where else the corrective actions
are the actions taken to mitigate the existing hazards which may eliminate the risk permanently.
The corrective action focuses on the isolation, engineering control and the PPE.
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6.1.1 Proposed Control Measure for Working at Height Safety Hazard
Elimination Isolation
ground level.
be in place.
working platforms.
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Administrative Control
place.
workforce periodically.
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PPE
safety glasses.
carabineer.
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6.1.2 Proposed Control Measure for Ergonomics Health Hazard
Elimination Isolation
NA NA
to be provided to work.
Administrative Control
ergonomics
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exercises.
working.
ergonomics.
PPE
activity.
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6.2 Propose Review Program for Control Measure
The elimination method that can be used for this hazard is by working at the ground as
far as applicable. If situation requires the individual to work at a height, this elimination step
A proper equipment should be worn to ensure that the equipment suits the particular
Every scaffolds that are built should have hook off points to ensure the hooks are strong
on the tubes. The scaffold tubes should also be certified by the competent personal. This step is
to avoid any miscalculation by regular personal and causing the system to fail at the place.
Engineering constructed scaffold platform should be built complete with all the safeguards such
as guardrails, handrails, toe boards and proper safety nettings to avoid any fall id any slip and
trip occurs. Anchor points should also be in place to ensure the harness helps to arrest the worker
Working at height procedure should be in place and all the details especially on the usage
of the harness and the prevention of fall methods should be specified in the procedure. Review
on the procedure should be done yearly to progressively improve the system in place. Trainings
for those who will be working at a height should be done periodically and the usage of the PPE
associated to the activity should be done. Toolbox talk should be given prior to start work to
ensure that a refresher session on the hazards is spelled out and control measures are in place.
Signages and other safety communications such as safety alerts, bulletins should be in
place to alert the workers on the hazards at the area. Inspection on the scaffold or elevated
working platform should be done every week and in any adverse weather change to ensure the
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structure is safe to use. The structure is controlled by the tagging system which will be approved
An appropriate PPE for this task should be worn by the employees working above 2
meters of height. The lanyards that are used should have double or triple karabiner to ensure it
helps from falling much lower to the ground. The lanyards should be inspected by the user prior
to use and the methods of checking the lanyards should be taught during the trainings and even
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6.2.2 Review Program for Ergonomics Hazard
This hazard cannot be eliminated as it is the effect from the employee / worker itself and
is caused due to the wrong posture of the individual. A proper working platform such as
engineering constructed bench or scaffold benches should be provided to ensure a proper sitting
or standing posture could be adhered. The tools that are used for the particular activity should
also be engineering designed especially for a proper grip to avoid carpel tunnel syndrome in long
Procedures on the proper lifting method, sitting methods and handling tools should be
spelled out in the procedure. This will avoid the effect of back pain, muscle strain, fatigue and
many more.
Specified trainings for all the workers working in structures which require them to work
in awkward postures and position should be given to educate the workers on the hazards of bad
positioning the body and working in a wrong posture for extended hours.
An exercise program should be done for all workers prior to start work. This is important
to have a good blood circulation and to release all the muscle cramps and muscle pains. A break
of 5 minutes to stretch the body for an extended working for every hour should be mandatory to
Toolbox talk on the importance of working positions and lifting methods should be
cascaded periodically to ensure shortcuts are not taken for a healthier body. In certain areas
while lifting more than 20kg depending on the weight of the person is not encouraged.an
evaluation on the maximum load that should be carried by the worker should be specified and
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6.3 Benefits of The Recommendation
The recommendations are given to ensure the safeguards of employees are taken care of
in a good manner. The implementation if these recommendations could reduce the risks
associated to the hazards specified. This will result in a LOW risk level which will not require
any further action. This directly will result in a safe working environment with increased
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7.0 REFERENCE/ SOURCES
Books and notes:
a) Occupational Safety and Health Act 1994
b) Factory and Machinery Act 1967
c) Safety and Health Officer Module I,II, III, & IV
d) Guidelines for Hazard Identification, Risk Assessment and Risk Control
(HIRARC), Department of Occupational Safety and Health (MOHR), 2008,
JKKP DP 127/789/4-47, ISBN 978-983-2014-62-1
e) Scaffold Erector SCF-1 (Level 1) Basic Scaffolding Course by Academy
Binaan Malaysia.
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8.0 APPENDICES
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