OHS issues in construction machinery

I
Acknowledgement

II
Abstract

III
Index

Acknowledgement.......................................................................................................................................II
Abstract......................................................................................................................................................III
Index..........................................................................................................................................................IV
1.1 Background of the project...........................................................................................................1
1.2 Research problem........................................................................................................................2
1.3 Aim of study.................................................................................................................................2
1.4 Objective of the study..................................................................................................................2
Chapter 2.....................................................................................................................................................3
2.1 Introduction.................................................................................................................................3
2.2 Overview of construction sites....................................................................................................5
2.3 Construction sector in Sri Lanka..................................................................................................7
Chapter 3.....................................................................................................................................................9
3.1 Introduction.................................................................................................................................9
3.2 Research methodology..............................................................................................................14
3.3 Questionnaire for construction site...........................................................................................14
3.4 Questionnaire for agent of machine in Sri Lanka.......................................................................15
3.5 Questionnaire chart to apply here.............................................................................................15
3.6 Case study 01.............................................................................................................................15
3.7 Case study 2...............................................................................................................................16
3.8 Data analysis..............................................................................................................................17
Chapter 4 Conclusion.............................................................................................................................19
Chapter 5 Recommendations.................................................................................................................20

IV
1.1 Background of the project.

Machineries are used in construction works caused accident due to various reasons, Heavy
machineries are an important part of construction.

Construction machines significantly decrease building time by increasing productivity; cranes

perform lifting functions once handled by pulleys and backbreaking human labor of lifting. A
backhoe can dig a hole in a few minutes, a task that once required a team of workers with
shovels.

Despite the gains in efficiency, working around these massive and powerful machines comes
with an inherent risk. In fact, heavy machinery accidents are among the most frequent causes
of workplace injuries on construction sites.

Among the accident in construction sites power tools, machineries and road vehicles are taking
leading part this project is mainly focus on issues of machines and related technical
backgrounds.

Machines are generally used in construction sector,

 Articulated loaders
 Backhoes
 Bulldozers
 Cherry pickers
 Compactors
 Cranes
 Dump trucks
 Light vehicles
 Power tools
 Warehouse equipment and machinery
 Forklifts
 Excavators
 Front loaders
 Paving machines
 Power shovels
 Road graders
 Scrapers
 Air compressor
 Track drills

1
 o research problem
Identifying reasons for accident involving machines on following reasons,
 Unskilled operations of specific machine

1.2 Research problem

Identifying reasons for accident involving machines on following reasons,
 Unskilled operations of specific machine
 Wrong selection of machines for appropriate work
 Poor maintenance of machines
 Overaged machine
 Insufficient knowledge of the technical knowhow of machines
 Use in unsafe environment

1.3 Aim of study

minimize the rate of accident involving machines use in construction sector.

1.4 Objective of the study

study the rate of accident in construction site involving machines
identify the OHS issues in the machines
propose strategies to avoid accident due to operation of machines

chapter 02 Methodology,

Literature review

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Chapter 2

2.1 Introduction
Accidents related with construction machines in operation are seriously affected on the human
life/activities and finally on productivity of the construction filed. The rates of accidents are depending
on various reasons but directly on number of machines and their operations. Then it is clear that
preventive measures must be strongly adapted according to the increasing of machineries and their
operations.

Heavy machinery is present at many construction job sites and this complicated equipment needs to be
maintained and operated under supervision. When employees aren't trained, safety precautions are
ignored, or equipment isn't inspected regularly, dangerous or even fatal accidents can occur.

Type and depth of preventive measures are varied on type of work, selected machines and other
physical factors.

There are many ways in which a heavy machinery accident can happen. Following type of
accident happen to construction machines.

 Rollovers. Rollovers occur when a machine loses balance and topples to the side. These
accidents commonly occur when the operator loses control, the ground is unstable, or
the machine is poorly maintained.
 Collapses. A collapse occurs when the machine buckles under the weight of its cargo
and crumples to the ground. These accidents frequently occur with cranes.
 Malfunctions. A malfunction occurs when a machine loses its grip or fails to perform its
job. The effects can range from loss of control to accidentally dropping a heavy item or
items on workers below.
 Machine collisions. A collision is defined as when a machine runs over a worker or pins
him between a hard surface. These accidents commonly occur when the operator loses
control of the machine or the machine is left running but unattended.

Some of the most-common factors involved in heavy equipment and machinery accidents
include:

 Backing up
 Colliding with a stationary object
 Colliding with another piece of equipment
 Dropped loads
 Machinery entanglement
 Failure to check blind spots
 Objects falling from forklifts and other equipment
 Pinning workers between equipment and stationary objects

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Heavy equipment and machinery accidents are among the leading causes of serious and fatal
accidents on construction sites, and safety standards governing the use of powered industrial
trucks (such as forklifts) on jobsites are among those most-commonly violated by employers.
Unfortunately, accidents happen even in the safest working environments,

Construction workers are responsible for building the homes, office buildings, stores and other
parts of the infrastructure that comprises our modern world. Construction workers work with
all manner of heavy equipment during their work day. When construction equipment
malfunctions because of deferred maintenance, or because of a manufacturing or design
defect, or if a worker is injured using a piece of equipment that was unguarded, it can lead to
horrifying injuries and even workplace fatalities. The following are a few examples of heavy
equipment which can cause construction accidents:

 Articulated loaders  Forklifts

 Back end loaders  Hydraulic lifters and excavators
 Backhoes  Excavators
 Bulldozers  Front loaders
 Cherry pickers  Paving machines
 Compactors  Pay haulers and pay loaders
 Cranes  Power shovels
 Crawlers  Road graders and rollers
 Dump trucks  Scrapers

As an example some other causes of crane accidents include:

 Misunderstood signals between workers

 Negligent operator
 Inappropriate use of the crane
 Improper boom angle
 Improper assembly of the crane equipment
 Cranes colliding with power lines

Construction industry has more workplace deaths per year than any other industry. Heavy machinery
and construction equipment plays a part in many of the deadly construction site accidents. But most of
these accidents are preventable if proper precautions are followed.

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Heavy machinery accidents usually do not just happen – more often, someone was careless or
there was a flaw with the equipment. Factors include:

 Equipment was not designed safely

 Machinery has not been routinely maintained
 Workers are not properly trained and/or supervised
 Workers do not operate the machinery properly
 Equipment does not display proper safety warnings

These factors can lead to serious, and even fatal accidents through:

 Misused vehicles
 Failed machinery, including failing compressed air lines, hydraulic pumps, or cables
 Improper use of safety equipment
 Operator error
 Getting body parts, jewelry, and clothing caught in machinery

2.2 Overview of construction sites

The size of construction sites is beyond manual working capacity the use of machineries are essential to
carry out the work in order to achieve the target within given period of time.

Working force of construction site includes following categories,

1.managment (directors/managers/engineers etc.)

2.supervisores (team leaders/foremen/officers etc.)

3.skilled workers (machine operators/technicians/masons/plumbers/store keepers etc.)

4.semiskilled workers (machine helpers/assistant mechanics/assistant plumbers etc.)

5.unskilled workers (manual workers/cleaners/labors etc.)

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6
 ORGANIZATION CHART
OF THE CORPORATION
Project Manager

Deputy Project
Manager

Safety Manager Quantity Surveyor Engineer Admin Officer

Machine Operator Vehicle Driver Office Workers

Foreman

Mechanic

Labor

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Building and material

Admin office

Project manager office

Material store

Safety office

Vehicle yard/workshop

Workers rest room/dining area/washing area

Security office

Machine requirement

Light vehicles (double cab/crew cabs/cars etc.)

Heavy vehicle (tippers/trucks/tractors/bowsers/truck mixture etc.)

Machines (backhoe loaders/excavators/skid loaders/wheel loaders etc.)

Machine in workshop use for heavy machinery maintenance such as,

Air compressors, lath machines, power drill, machine lifters, welding plant etc.

2.3 Construction sector in Sri Lanka.

The construction industry of Sri Lanka has become a key driver of economy and it is necessary
to sustain this growth by facilitating sectoral development.

It is necessary to introduce modern technology to the industry and train more people to make it
a vibrant sector in the economy, construction industry contributes 7.1 percent to the GDP while
there has been a steady growth over the years.

The industry faces many challenges such as labor and the high cost of raw materials. The
government has introduced a training program for youth to engage in the industry and secure
employment while providing training to gain the skills needed by the industry. Therefore, the
government expects that the youth will take this opportunity to further their skills and secure
employment as there is a high demand for construction related jobs in the market,

Sri Lanka need foreign collaboration in completing mega construction projects. This will ensure
transfer of knowledge, skills and technology to our country and the industry will benefit in the
long run. However, it is important to address the issues in the industry and attract and train
more youth to fill the job vacancies for the construction industry to move forward.

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Machines in the construction sector act a huge part in construction filed in order to increase the
productivity and accuracy in reaching the planned target. However, fleet of machine can make
disaster in finance and safety culture if not take care of them and spend some amount of
money that gain from their operation. Maintenance of machines is the key factor of long-lasting
and trouble-free performance including safety of operates and people in site.

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Chapter 3

Research: OHS issues in construction machineries

3.1 Introduction.
Machineries are essential part of each and every construction work even in basic carpentry work use
electric drill, sewing machine etc.

Type of machine use in construction sector.

 Backhoes and loaders

 Bulldozers

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 Cherry pickers

 Combines and other farming equipment

 Cranes

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12
 Dump trucks

 Electric hand trucks

 Excavators

13
 Forklifts

 Industrial and factory machines

 Trenchers

14
  Warehouse equipment and machinery

As long as a machine is in operation there is a risk irrespectively the size of the machine. At a place
where a lot of machines are in operation the high rate of risk existing. In order to minimize risk at
construction sites it is compulsory to adopt high rate of safety procedures.

In spite of such safety procedures rate of accident relating to construction machines are increasing in
construction sector in Sri Lanka. Some accidents are not discovered as not purposely exposed due to
various reasons.

Intention of this project is to discussed the actual reasons for accident and suggest preventive measures.

Minimizing of accident not only affect to the people who involve in the process and machines but also
whole construction sector.

Following figures explain how accident effect to the productivity.

Loss of Man hours due to accidents,

Singapore {www.wshc.sg}

Year Loss of man hours

2009 258,421

2010 239,137

2011 170,366

2012 206,845

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2013 274,183

2014 245,987

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3.2 Research methodology
A comprehensive survey is carried out to find out OSH issues in construction machines and reasons
leading them causing accidents.

Questionnaire survey is effective method of data collection using in the research with aid of following
organizations.

Government construction site and workshops

Semi government organizations

Private sector construction sites and workshops

3.3 Questionnaire for construction site.

 What type of machines are in operation at your site?
 Out of those machines which machines involved accidents frequently?
 According to your records any particular type of machine meet accident at considerable high
rate?
 Any operator involved considerably high rate of accidents?
 All machine operators are confident of operation of their machines?
 Are machine operators being given training periodically specially with new type of machine?
 Do all machines are maintained properly according to the manufacture’s recommendations?
 The technical team of machine maintain are trained and confident of service your machine
fleet?
 Do you train Safety officers about safety features of machines and do they inspect machines
accordingly?
 Is there a system to identify operators who operate machines are trained for particular
machine?
 What are the procedures of investigations you apply for operator after accident?
 What are the procedures you apply for the machine which met an accident for fitness of
particular work?
 If you noticed any machine meeting accident repeatedly what steps you take to find the reason?
 Have you any records that operator or any other person getting injury sitting inside the cabin or
while cleaning the machine which is at idle?
 Can I have brief details of accident investigating system apply in your company.
 Is there any possibility for me to have complete details of machine accident and investigations
for past 03 years?

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3.4 Questionnaire for agent of machine in Sri Lanka.
 Do you sell brand new machines as well as reconditioned?
 Do you train operators about the operation/safety of machine sold irrespectively brand new or
reconditioned?
 Do you train technical teams of customers of maintaining the machine with safety features?
 Do you keep adequate stoke of original spare parts for your machines?
 Do you recommend using spare parts other than OEM?
 Can all customers have service manual of all machines you sell?
 What action do you take if any machine involved accident due to machine failure?
 Do you update safety procedures of machines you sold according to the principal’s instruction?

3.5 Questionnaire chart to apply here

Apply

3.6 Case study 1

Synopsis of accident

 The injured technician had a task to replace tire of a heavy equipment (aircraft tow tug).
 After replacing new tire needs air inflation, these tires should be filled with Nitrogen.
 Nitrogen cylinders are fitted on a wheel cart, on which had display of instructions for safe
operation.
 Max: pressure of nitrogen cylinders are 3000psi,
 Necessary regulating system/gauges/valves/hoses fitted on the same cart.
 Pressure required for the tire was 110 PSI
 While operating suddenly jumped the output hose which connected to the tire braking its metal
connecter fitted to the tire valve.
 The broken end with sharp point hit the technician shoulder penetrating into his skin.

Observation and finding

 the instruction was clearly indicated that the regulating valve must be kept to Zero pressure
before and after using the plant.
 After reconfirming the position of the regulator only the cylinder valve to open. Then regulator
can be operated till required pressure read on the low pressure gauge.
 Now can open the output valve and fill the tire.
 The technician had asked his assistant to operate the plant without prior instruction for safe
operation.
 The assistant had open the output valve directly without checking the regulator position
Unfortunately, the regulator was in the position of its maximum.

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  This high pressure caused to burst the hose.
 The injury was small but nitrogen gas gone to his blood stream keeping his life at extremely risk.
 He had been keeping in a pressurized room for 02 weeks till his blood is completely free from
gas nitrogen.

Lesson learned

 Persons who are on the job must be familiar with the plant they use.
 All technical staff must be trained for operating plants in the workshop.
 Helpers assistant are not allowed to operate plant with high risk.
 After using make sure the plant must be in neutral position.

3.7 Case study 2

Synopsis of accident

 Security personal death as a result of accident by huge vehicle (aircraft tow tug)
 The operator who drive the machine at the time, was stopped by security personal for regular
check-up.
 After check he was allowed to enter the machine to restricted area.
 As soon as he started to move another security personal approached in front of the machine.
 The operator had no alternative other than apply the brake.
 Unfortunately, the brake was not activated and hit the security personal casing serious injuries
ending his life.

Observation and finding

 The operator was with good experience and trained for operating such machine.
 The brake system failed due to a burst hydraulic hose leading to main brake booster.
 Emergency brake system also not activated due to electrical failure.
 One switch had been fitted to operate special pressure pump if brake pedal reach its bottom
stop point.
 This switch had not been checked for a long period of time causing stuck with dust and
corrosion.

Lesson learned

 Poor maintenance caused for this death.

 No educate supervision on maintenance and after inspect
 The check sheet was not properly filled, if went through, this point (switch) must have been
noticed.

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3.8 Data analysis
Highlighted points of Questionnaire and interviewing.

 Road vehicle (belongs to site) accident rate are much higher than site machines,

Reason:

comparatively speed is high and usage and moving distance expose to risk is higher than machines
working in site.

Drivers are not in superiors’ vicinity may leads to act indiscipline.

 Tippers are considerably in high side of meeting accidents.

Reason:

Tippers are machines that moving frequently in the site as well as out of the site.

The ground condition is always uneven/slippery/soft in which operating make very difficult and risky.

As per the records worn-out tires were fitted on tippers which met accident frequently. (poor
maintenance)

Brake problems had been left unattended even drivers complained time to time (poor maintenance).

Interviewing drivers who met accidents noted that they had not undergone any safety driving training at
all.

 Operating machines by operators other that assigned for same machine meet accident and
damaging machines.

Reasons:

Interweaving such operators observed that some machine had defect not attended and familiar with the
existing operator but not informed the temporary operator. (poor communication between employees
and bad maintenance)

The operating style and speed suddenly change not adapted by the machine.

The new operator does not aware of the fitness and condition of the machine and he is not willing to
study the machine as he is working for day or two.

 Not properly selecting machines for required type of work.

Supervisors who responsible for work arrangement not select correct machine fit for the purpose.

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It was obviously noticed accident such as overturn/stuck in mud/collided with live wires/ machine
damaged due to poor preparation of the work place and not inform operator in advance.

Poor supervision and improper arrangement.

 Defective machines deploy for work.

This is an unacceptable activity done by supervisors and force to operators in order to reach their
targets.

going through accident report of sites above was observed. This action creates so many problems
creating accident/personal injuries/property damage/machine damage etc.

unprofessional act of responsible officers.

 Repairs carried out with unskilled persons and with duplicate parts.

Observed considerable rate of incident due to improper repair to the machines. Instead of original
manufacture parts fixing low quality parts that no long lasting and not withhold the required load.

This is mostly done by unskilled personals and no proper supervision.

New machine mat with and accident due to not following proper instruction of manufactures and not
proper training provided by the local agent.

Specially used machine imported from various importers have no technical team or qualified workers to
train their customers.

Above to be high lighten in conclusion

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Chapter 4 Conclusion

Machine operating even by an operator who is without familiarization on same type of machine, lead to
accidents.

The machine selection should be strictly monitored for compatibility for the work to be performed.
Failing to do so Machine damage/property damage/personal injuries may result.

No circumstance deploy machine with defect or without properly repair.

Machine repair/maintenance must be performed by qualified technical people and must use OEM
(original equipment manufacturer) parts.

Machine importing and selling without educate knowledge in operation and technical aspects of them
are compulsory. Releasing machine without proper instruction of such machine by importers is felling
uses at high risk.

Machine deploying for work without pre-inspection of arrangement the place and surrounding area may
lead to accident

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Chapter 5 Recommendations

Operator selection to operate machines is a very important factor which should be done by a very
experience/competent person who may possess a permit as an instructor.

Machine must be properly maintained with OEM (original equipment manufacturer) parts.

Operating procedure of machine are different according to models hence knowledge must be updated
by competent person or qualified personal from local agent according to the manufacture instruction.

Those who are Used machines importing to Sri Lanka must be accompanied with a qualified team for
maintenance and operation of their machines.

Above requirement is to be monitored by government for submitting their import permits.

Pre inspection of heavy machine must be carried out by a competent person and issue permit to use for
the assigned work.

Qualified competent person must do appointed to inspect the place where work to be performed in
order to identify the safety issues and eliminate.

END

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