Candidates Observation Sheet 1 Us Man

INTERNATIONAL GENERAL
CERTIFICATE
Candidates observation
Sheet
IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION
Sheet number 1 of 8
Student name: Muhammad Usman
Student number: 00268752
Place inspected: FAZAL Steel (Pvt.) Ltd. Islamabad, Pakista Date of inspection: 26/January/2015
CERTIFICATE
Observations
Control measures
Immediate and longer term
actions
Timescale
Immediate action:
Give instructions about the
safe methods of manual load
handling.
Installation
of
Pictogram
boards of safe techniques of
manual handling.
Immediately
Hazards and consequences:

It may cause back pain and musculoskeletal disorders,
which result in increase of absentees of workers.
Long-term actions:
Over-head crane should use
to unload the billets from truck
to the conveyor belt.
4-5 Weeks
2. Location: Re-rolling Mill
Immediate action:
Mark the path using lime
powder.
Immediately
4-5 Days

Collision of workers and the loading truck which may
result in severe injury.
Long-term actions:
Permanent colour marking of
the tracks by paints and
keeps it permanent by timely
re-colouring.
3. Location: Water Turbine Unit
Immediate action:
Cordon off the stairs and use
ladder to reach on the top.
Hazards and consequences
1. Location: Pre-Heating Furnace, Re-rolling mill

Observation:
Workers were manually unloading the billets from the
truck to the conveyor belt of pre-heating furnace, the
postures of the workers were totally wrong and against
health and safety
Observation:
No proper marking or any designated routes for the
safe movement of loading trucks and pedestrians.
Observation:
Flow pipe line for supplying cold water from Water
Turbine Unit to TMT was passing from the stairs of
Turbine unit which has lessen the space on the stairs
for the worker and was an obstruction.
The worker can fall on the ground as well as in the
tanks of hot water coming out from the re-rolling unit
for cooling which may result in fracture of bone in case
of falling on the ground as well as severe burning in
Long-term actions:
Move the pipe line away from
the stairs.
3-4 Days
Immediately
1-2 Weeks
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 2 of 8
case of falling in the tank.
Immediate action:
Carry on the good practice.
4. Location: Control booth, Re-rolling mill
Observation:
Emergency Stop buttons for every single machine
were present and were prominent as well as clearly
displayed which are helpful to stop the process in case
of any emergency situation
Ongoing
Monitoring
Long-term actions:
Hazards and consequences: N/A

Immediate action:
Stop the work and put the
safety guard
Immediately
Long-term actions:
Check the guard before
starting the machine.
Keep the maintenance of the
machine and always.
Everyday
3-4 Days
6. Location: Steel Re-rolling Mill
Immediate action:
Posting proper fire exit sign
boards with proper lighting.
Observation:
There was no fire exit present in the whole Steel Rerolling Mill and no identified sign boards regarding the
fire exit was present
Long-term actions:
Keep the check of fire exit
sign boards and maintain it.
Managing fire drills.
5. Location: Shear M/C, Re-rolling Mill

Observation:
Safety Guard on the shaft of manually operated Shear
machine was not present and the belt was uncovered.
It may result in the entrapment or entanglement of the
worker dress which may result in injury or death.
1 Week
1 Month
2-3 Months

Absence of the instructions about fire exit may cause
the worker to run towards the wrong side in case of
emergency which may lead to death or very severe
injury i.e. burn.
7. Location: Water Turbine Unit

Observation:
There were large underground tanks for the cooling
Immediate action:
Place the barrier and no entry
tape on the paths towards the
tanks
Long-term actions:
Immediately
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 3 of 8
and recycling of hot water for TMT unit which are
uncovered to cool down the water by expansion in
fresh air, no protected grill or any kind of guardrail was
present around the tanks.
The absence of guardrail may result in fall of the
worker in the hot water which can be a very severe
burn or even death due to the presence of hot water,
and fall hazard in the absence of water resulting
fracture.
8. Location: Control room, Re-rolling Mill
Robust Fencing around the

tanks and warning sign
boards should be installed.
2-3 Weeks
Immediate action:
Ongoing
Monitoring
Long-term actions:
Observation:
Properly managed and fully equipped first aid box was
present for the provision of first aid to the worker in
case of any emergency situation.
Immediate action:
Stop the work and fix the side
guards.
9. Location: Intermediate Stand, Re-rolling Mill

Observation:
The red-hot steel coming out of the pre-heating
furnace rolls over the rough stand and then on
intermediate stand, but there were no side guards
present there to prevent the slipping out of the hot
steel bar from the rollers, which was one the main
cause of accident in the mill.
It may cause damage to the machinery equipment as
well as damage to the workers i.e. Severe burn.

Observation:
People working with red hot steel bars emitting InfraRed Rays, which are harmful for eyes, were not using
proper Goggles or any kind of Personal Protective
Immediately
Everyday
Long-term actions:
Before starting the mill, check
out the side guards.
Immediate action:
Immediately provide the
goggles/ face protector to the
worker
Immediately
Long-term actions:
Provide Instructions and
information.
1 Week
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 4 of 8
Equipment for their eyes.
Absence of Goggles or any such PPE may cause
Retinal burn and development of eye contracts over
time.
Observation:
Water cooler and glass was very dirty, contaminated
with oily and greasy material because of the workers
polluted gloves/hands.
Drinking oil and grease contaminated water may cause
cancer incidence, pulmonary ailments, and
psychological, reproductive, and dermatologic health
problems.
Carry out strict action/fine

against the violence of
wearing safety goggles by
inspection.
Immediate action:
Clean the cooler and replace
the glass.
2-3 Weeks
Immediately
1 Day
Long-term actions:
Wash the cooler and keep it
clean.
Immediate action:
Ongoing
Monitoring
Long-term actions:
Observation:
The overall housekeeping of the whole steel re-rolling
was good, the floor was clean; there was no spillage of
any oil etc. As well as no contamination on the surface
of floor.
13. Location: Steel Re-Rolling Mill

Observation:
There was no prohibition of smoking and neither any
prohibition sign board nor any other statement
regarding No Smoking was displayed.
No prohibition of smoking may increase the probability
of fire which result in huge damage of the mill as well
Immediate action:
Posting No smoking sign
boards in the mill area.
Long-term actions:
Should take strict action
against smoking in No
Smoking zone.
2-3 Days
1 Week
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 5 of 8
as of workers
14. Location: Control Booth, Re-rolling Mill

Observation:
The process of Re-rolling is monitored and controlled
by the control booth present in Steel Re-rolling Mill but
there is only a stool with no back rest was present for
the worker.
Immediate action:
Provide adjustable and
moveable chair with proper
back rest.
3-4 Days
Long-term actions:
Maintain the chair in good
condition or replace it with
new one depending on its
condition.
3-4 Months

The absence of adjustable chair with proper back rest
may cause back pain as well as MSDs associated with
sitting in a fixed position for long periods of time.

Observation:
There was no toilet present in the Steel Re-rolling Mill
for the worker toilets are situated far away and outside
the Re-rolling mills area.
Wastage of time due to which work rate may be
disturbed, mental stress and fatigue

Observation:
The structure of the mill was good, properly ventilated
and lit; utilization of sunlight in day time was very good.
Immediate action:
Provide a toilet in the mill/
near the mill area with hand
wash basin and soap.
1-2 Weeks
Long-term actions:
Keep the toilet adequately
clean.
Twice a day
Immediate action:
Ongoing
Monitoring
Long-term actions:
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 6 of 8
Immediate action:
Provide ears muffs or ear
plugs to the workers.
Immediately
1-2 Days

Noise may result in temporary threshold Shift or
permanent threshold shift also it may cause stress;
noise induced hearing loss and tinnitus.
Long-term actions:
Keep the ear muffs clean and
free of contaminants.
Maintenance and provision of
insulation and isolation to the
machine producing noise to
minimize it.
18. Location: Shear Machine, Steel Re-rolling mill
Immediate action:
Put the cover on the
uncovered area.

Observation:
There was a lot of noise in the mill and workers were
not using any type of noise safety equipment.
Observation:
The cover over underground control wires which are
connected under the ground towards the control room
was not present.
Long-term actions:
Always check the cover
before starting the mill and
after the maintenance
process.
3-4 Weeks
Immediately
Everyday

The worker may fall into it which may result in injury
due to fall as well as electric shock due to the
presence of electricity.
19. Location: Control room, Steel Re-rolling

Observation:
There were large control panels i.e. PLCs present in
the control room producing heat due to which there
was suffocation in control room, also there was no
properly ventilation i.e. exhaust fan was not present.
Mental fatigue due to the absence of fresh air, also
result in stress.
Immediate action:
Install exhaust fan for the
circulation of fresh air.
Long-term actions:
Install Air Conditioner to keep
the huge PLCs units cool as
well as the environment of the
control room fresh.
1-2 Days
3-4 Weeks
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 7 of 8

Observation:
There was only one fire extinguisher present in the
whole Steel re-rolling mill, which was very alarming.
Absence of fire extinguisher or inappropriate number
of fire extinguisher may be very dangerous in case of
fire because fire cannot be controlled at its early stage
which may result in huge damage.
21. Location: Control Room, Steel re-rolling mill

Observation:
The locks of PLC units were not working properly and
can be open by anyone who is not properly designated
for controlling these units.
Due to easy excess to the boards any irrelevant
person can try to see it or may check different controls
which may result as accident for other workers near
machines or electric shock for the person who is
indulging with the boards.
22. Location: Steel Re-rolling Mills

Observation:
The emergency alarms were properly fitted at different
places in the whole steel re-rolling mill to alert people
in case of any emergency situation.
Immediate action:
Provide adequate number of
fire extinguishers on
prominent places.
2-3 Days
Long-term actions:
a. Inspection of fire
extinguishers.
b. Conduct fire drill exercises
periodically.
a. Year
Immediate action:
Out of Bound signs for
unauthorised person should
be pasted on the door of the
control room.
Immediately
Long-term actions:
Fitting of new locks.
The keys of the locks should
be in control of the
responsible person to avoid
misuse.
Immediate action:
b. 2-3 Months
3-4 Days
Ongoing
Monitoring
Long-term actions:
Immediate action:
2-3 Days
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 8 of 8
23. Location: Steel Re-rolling mill
Observation:
The workers working in the mill were paid per hour/ per
ton of the production work instead of paying per day.
Workers will prefer to work more to earn more money
and will give less priority to safe working which results
in increase in accident rate, also its mental fatigue for
the workers.
Provide Instructions to the

workers to prefer safety
instead of speedy unsafe
working by notices and
circulars.
3-4 Weeks
Long-term actions:
Pay the work per day instead
of paying per hour / per ton.
Promote safety culture.
Immediate action:
Stop the work and keep the
cylinder in upright direction.
Observation:
There was some maintenance work ongoing in the mill
and the workers were doing hydrogen gas welding
there without considering any safety precautions. The
cylinder was laid down and was not in upright direction
and there was no proper lifting cradle for its
movement.
Long-term actions:
Always use cradle for the
movement of cylinder instead
of rolling.
Strict action against the
violence of rules.
Immediately
3-4 Days

As hydrogen is flammable gas and laying down its
cylinder may cause fire or blast.

Observation:
There was no safety sign and any kind of hazard or
prohibition sign at all on any machine, PLC boards.
Absence of signs may lead to ill health and accidents
i.e. Electric shock, entrapment and entanglement
because of no information provided to the workers
about hazards.
Immediate action:
Postage of hazard signs as
well as machine safe using
techniques sign boards
should installed on the
appropriate places.
Long-term actions:
a. Provide Information and
instructions to the worker to
work safely.
b. Periodic inspection of the
sign boards.
Immediate action:
2-3 Days
a. 1 Week
b. 2-3 Months
Ongoing
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 9 of 8
26. Location: Steel Mill
Observation:
There was proper life insurance policy for every worker
working in the Mill.
Long-term actions:
Monitoring
27. Location: Shear Cutting Machine, re-rolling Mill
Immediate action:
Provide hard shoes
gloves.
and
Observation:
Workers are not wearing hard shoes and gloves during
the cutting operation of steel bars.

Cuts injury may occur as well as fall of steel bars on
the feet may cause injury to the feet.
28. Location: Shear Cutting Machine, Steel Re-rolling

Mill
Observation:
The product i.e. steel bars were loading on the loading
truck by means of over head crane, which reduce the
hazards of back pain and injuries due to manual
handling.
1 Day
Weekly
Long-term actions:
Conduct timely survey to
ensure the usage of Personal
Protective Equipment by the
workers.
Immediate action:
Ongoing
Monitoring
Long-term actions:
.
29. Location: Beside Shear machine, Steel Re-rolling

Mill
Observation:
Workers working under the over head crane are not
wearing hard helmets.
Immediate action:
Provide hard helmets to the
workers
Never allow the workers to
worker when crane is exactly
over them.
Immediately
Long-term actions:
Daily
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 10 of 8

Object fall hazard was present which may injure the
head of worker and can cause even death.

Observation:
The mill was good for working in day time in the
presence of sunlight, while working in the night is not
suitable due to improper lighting; many lights were out
of order.
Discomfort the worker, inability to concentrate; the
worker may collide with any machine which can cause
injury or even death.
Take strict actions against the

workers not using PPE by
surveying and inspection.
Immediate action:
Use emergency lights in the
night shift.
Make the light in work order
Long-term actions:
Periodic maintenance of the
lights and maintain the
appropriate light lux level in
the mill.
Immediately
2-3 Weeks
CERTIFICATE
Sheet
IGC3 THE HEALTH AND

Sheet number 11 of 8
(2011 specification)
sheet
IGC3 THE HEALTH AND

Sheet number 1 of 8

Place inspected: FAZAL Steel (Pvt.) Ltd. Islamabad

Date of inspection: 26/January/2015

Candidates Observation Sheet 1 Us Man

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INTERNATIONAL GENERAL

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

Hazards and consequences:

2. Location: Re-rolling Mill

Hazards and consequences:

3. Location: Water Turbine Unit

Hazards and consequences

1. Location: Pre-Heating Furnace, Re-rolling mill

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

Hazards and consequences: N/A

6. Location: Steel Re-rolling Mill

5. Location: Shear M/C, Re-rolling Mill

Hazards and consequences:

7. Location: Water Turbine Unit

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

8. Location: Control room, Re-rolling Mill

Robust Fencing around the

9. Location: Intermediate Stand, Re-rolling Mill

10. Location: Steel Re-rolling Mill

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

11. Location: Steel Re-rolling Mill

12. Location: Steel Re-rolling Mill

Carry out strict action/fine

13. Location: Steel Re-Rolling Mill

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

14. Location: Control Booth, Re-rolling Mill

Hazards and consequences:

15. Location: Steel Re-rolling Mill

16. Location: Steel Re-rolling Mill

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

Hazards and consequences:

18. Location: Shear Machine, Steel Re-rolling mill

17. Location: Steel Re-rolling Mill

Hazards and consequences:

19. Location: Control room, Steel Re-rolling

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

20. Location: Steel Re-rolling Mill

21. Location: Control Room, Steel re-rolling mill

22. Location: Steel Re-rolling Mills

Hazards and consequences: N/A

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752

Provide Instructions to the

24. Location: Steel Re-rolling Mill

Hazards and consequences:

25. Location: Steel Re-rolling Mill

IGC3 THE HEALTH AND

Student name: Muhammad Usman

Student number: 00268752