BACHELOR IN SCEINCE (HONS) CONSTRUCTION MANAGEMENT (CFAP246) UNIVERSITI TEKNOLOGI MARA (UITM SHAH ALAM) QUALITY, SAFETY, HEALTH AND ENVINROMENT CMA 483 REPORT TITLE: CONCRETE WORKS FACULTY OF ARCHITECTURE, PLANNING & SURVEYING, COLLEGE OF BUILT ENVIRONMENT, CBE CONCRETE W O R K S NO NAME NO MATRIC NUMBER 1. ZAHIRAH AIMI BINTI ZAINAL 2023941687 2. UMMI RAIHANAH BINTI MOHD FAIDZAL 2023756155 3. ZULSUZINARNI BINTI MAT ARIFFIN 2023319551 4. SYARIFAH ALIA BINTI SYED ZUBIN 2023322691 Session : Semester 1- 2023/2 Submission Date : 4 June 2023 Prepared For : Mrs Fazeera Binti Ujin
1 INTRODUCTION ....................................................... 1 1.1 HAZARD IDENTIFICATION AND RISK ASSESSMENT ............... 1 1.2 PURPOSE OF HIRARC ............................................... 2 1.3 TERM AND DEFINITIONS ............................................ 2 1.4 HIRARC ACTIVITY PLANNING ...................................... 3 1.5 PROCESS OF HIRARC ............................................... 3 1.5.1 WORKPLACE HAZARAD IDENTIFICATION ...................... 4 1.6 RISK ASSESSMENT ................................................... 5 1.6.1 LIKELIHOOD ....................................................... 5 1.6.2 SEVERITY .......................................................... 5 1.6.3 TABLE OF RISK .................................................... 6 2 BACKGROUND OF CASE STUDY .................................... 7 2.1 LOCATION OF CASE STUDY ........................................ 7 2.2 ABOUT OF CASE STUDY ............................................ 8 3. FACTOR IN THE ACTIVITIES THAT MAY CAUSE INJURIES OR ACCIDENTS ............................................................. 10 3.1 BATCHING & CASTING PROCESS .................................. 10 3.2 CONCRETING & VIBRATION PROCESS ............................ 10 3.3 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS BATCHING AND CASTING PROCESS ...................................................... 11 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS ................................................................. 12 3.5 ACCIDENT PREVENTION ............................................ 13 3.5.1 ACCIDENT PREVENTION FOR BATCHING AND CASTING PROCESS ...................................................... 13 3.5.2 ACCIDENT PREVENTION FOR CONCRETING AND VIBRATING PROCESS ................................................................. 15 3.6 HAZARD .............................................................. 17 4. DISCUSSION AND CONCLUSION ................................... 19 5. REFERENCES ......................................................... 19 TABLE OF CONTENTS
LIST OF TABLES LIST OF FIGURES FIGURE 1: FLOWCHAT OF HIRARC ..................................... 4 FIGURE 2: LOGO OF KUS PRE-CAST CONCRETE SDN BHD ...........7 FIGURE 3: LOCATION OF PRODUCTION FACTORY ................... 7 FIGURE 4: FACTORY LAYOUT AND PRODUCTION LAYOUT .......... 8 FIGURE 5: HAZE ......................................................... 11 FIGURE 6: CONCRETE TRUCK CRASHING ............................. 11 FIGURE 7: UN-STABLE CONCRETE TRUCK ............................ 11 FIGURE 8: CONCRETE BUCKET FALL ONTO GROUND ............... 11 FIGURE 9: WORKER SLIP ON WORKSPACES ........................... 12 FIGURE 10: VIBRATION TRANSMITTED INTO WORKERS HANDS AND ARMS ................................................................ 12 FIGURE 11: CONCRETE BUCKET FALLING ............................ 12 FIGURE 12: HEARING LOSS ............................................. 13 FIGURE 13: CONCRETE MOULD 3D BROKEN .......................... 14 TABLE 1: THE VALUE OF LIKELIHOOD ................................. 5 TABLE 2: THE SEVERITY VALUE ........................................ 6 TABLE 3: THE MAGNITUDE OF THE RISK LEVEL .......................6 TABLE 4: THE RELATIVE RISK LEVEL ....................................6 TABLE 5: THE INCIDENT BATCHING AND CASTING PROCESS ....... 11 TABLE 6: THE INCIDENT CONCRETING AND VIBRATING PROCESS . 12 TABLE 7: HAZARD IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL (HIRARC) IN CONCRETE WORK ....................... 17
1 1. INTRODUCTION 1.1 HAZARD IDENTIFICATION AND RISK ASSESSMENT WILL HELP YOU: People often think that incidents happen because of employee negligence or mistakes. However, most workplace incidents occur due to inadequate management controls. a. Identify and control workplace hazards. b. Create awareness among employees – and use it as a training tool. c. Establish risk management standards based on acceptable safe practices and legal requirements. d. Reduce workplace incidents. e. Save costs by being proactive instead of reactive. f. Effective management controls will raise the standard of health and safety measures. With HIRARC, one will be able to identify hazards, analyse and assess relevant risks and then apply appropriate control measures. In recent years, Hazard Identification, Risk Assessment and Risk Control (HIRARC) has become the basis of business planning, management, and operational practices as the basis of risk management. When conducting a workplace risk assessment many changes in work practices on site will be observed.
2 1.2 1.3 I. II. V. III. IV. PURPOSE OF HIRARC TERM AND DEFINITIONS a. To identify all the factors that may cause harm to employees and others (the hazards). b. To consider what the chances are of that harm actually be falling anyone in the circumstances of a particular case and the possible severity that could come from it (the risks) c. To enable employers to plan, introduce and monitor preventive measures to ensure that risks are adequately always controlled. Risk - A combination of the likelihood of an occurrence of a hazardous event with specified period or in specified circumstances and the severity of injury or damage to the health of people, property, environment or any combination of these caused by the event. Hazard identification - The identification of undesired events that lead to the materialisation of the hazard and the mechanism by which those undesired events could occur. Hazard control - The process of implementing measures to reduce the risk associated with a hazard. Hierarchy of control - The established priority order for the types of measures to be used to control risks. Hazard - A source or a situation with a potential for harm in terms of human injury or ill health, damage to property, damage to the environment or a combination of these.
3 1.5 1.4 VI. VII. HIRARC ACTIVITY PLANNING Risk assessment - The process of evaluating the risks to safety and health arising from hazards at work. It should be the duty of the employer to assign trained personnel to lead a team of employees related to a particular process or activity to carry out HIRARC. Risk management - The total procedure associated with identifying a hazard, assessing the risk, putting in place control measures, and reviewing the outcomes. HIRARC activities should be planned and carried out for situations where the hazard appears to pose a significant threat, or it is uncertain whether existing controls are adequate and before implementing corrective or preventive measures. HIRARC activities are also planned and managed by organizations that intend to continuously improve the Health and Safety Management System. PROCESS OF HIRARC Process of HIRARC requires 4 steps - a. Classify work activities b. Identify hazard c. Conduct risk assessment (analyse and estimate risk from each hazard), by calculating or estimating - i. likelihood of occurrence ii. severity of hazard d. Decide if risk is tolerable and apply control measures (if necessary).
4 Figure 1 : Flowchart of HIRARC 1.5.1 Workplace Hazard Identification To highlight the critical operations of tasks, that is those posing significant risks to health and safety of employees as well as highlighting those hazards pertaining to certain equipment due to energy sources, working conditions or activities performed. Hazard can be divided into three main groups, health hazards, safety hazards and environmental hazards. a) Occupational Health Hazard is any agent can cause illness to an individual. b) Safety Hazard is any force strong enough to cause injury or damage to property. c) Environmental Hazard is a release to the environment that may cause harm or deleterious effects.
5 1.6RISK ASSESSMENT 1.6.1 Likelihood The likelihood of the risk will be based how often the hazard will occur. The value of the likelihood is based on: LIKELIHOOD JUSTIFICATION RATING Most Likely Highly will happen or have happen before. 5 Possible Have a chance will happen and it’s not 4 impossible. Conceivable Maybe will happen with any additional 3 factor. Remote Still not clear about situation after several 2 operation. Inconceivable It’s unbelievable incident or never 1 happened before or never recorded it’s has happened before. Table 1: The value of likelihood. 1.6.2 Severity Severity can be determined based on the effect of the hazard to safety and health of the workers. This also includes the lost cost of company property if the accident happened. The severity value based on: SEVERITY JUSTIFICATION RATING Catastrophic Numerous fatalities, irrecoverable property 5 damage and productivity. Fatal Approximately one single fatality major 4 property damage if hazard is realized. Serious Non-fatal injury, permanent disability. 3 Minor Disabling but not permanent injury. 2 Negligible Minor abrasions, bruises, cuts, first aid type 1 injury. Table 2: The severity value.
6 1.6.3 Table of Risk The table of risk will be used after the severity and likelihood of the hazard was done. This will show the magnitude of the risk level. Severity 1 2 3 4 5 Likelihood 5 5 10 15 20 25 4 4 8 12 16 20 3 3 6 9 12 15 2 2 4 6 8 10 1 1 2 3 4 5 Table 3: The magnitude of the risk level. High Medium Low The relative risk level can be used to prioritise necessary actions to effectively manage workplace hazards. Table below determines priority based on the following ranges: Risk Action Level High A HIGH risk requires immediate action to control the hazard as detailed in the hierarchy of control. Actions taken must be documented on the risk assessment from including date for completion. Medium A MEDIUM risk requires a planned approach to control the hazard and applies temporary measures if required. Actions taken must be documented on the risk assessment from including date for completion Low A risk identified as LOW may be considered as acceptable and further reduction may not be necessary. However, if the risk can be resolved quickly and efficiently, control measures should be implemented and recorded. Table 4: The relative risk level.
7 2. BACKGROUND OF CASE STUDY Figure 3: Location of Production Factory Figure 2: Logo of KUS Pre-cast Concrete Sdn Bhd 2.1 LOCATION OF CASE STUDY This report focuses on the implementation of the HIRARC (Hazard Identification, Risk Assessment, and Risk Control) framework in the context of concrete work at KUS Pre-cast Concrete (M) Sdn Bhd. KUS Precast Concrete is a prominent company based in Ulu Tiram, Johor, Malaysia, specializing in the production of precast concrete products. With a strong commitment to workplace safety and health, the company has embraced the HIRARC framework to effectively manage hazards, assess risks, and implement control measures.
8 2.2 ABOUT OF CASE STUDY KUS Pre-cast Concrete (M) Sdn Bhd has established itself as a leader in the precast concrete industry, providing innovative and high-quality solutions for various construction projects. The company has built a solid reputation based on its expertise, state-of-the-art facilities, and commitment to delivering durable and sustainable precast concrete products. In line with its dedication to safety, KUS Pre-cast Concrete recognizes the importance of implementing comprehensive risk management practices. The HIRARC framework serves as a cornerstone of the company's approach, allowing them to proactively identify potential hazards, evaluate associated risks, and implement appropriate control measures to ensure the safety and well-being of their workforce. This report explores the background and practices of KUS Pre-cast Concrete (M) Sdn Bhd in relation to HIRARC and its application to concrete work. It examines the company's commitment to safety, including their organizational structure, key personnel responsible for health and safety, and the initiatives in place to promote a culture of risk management and continuous improvement. Furthermore, this report will delve into the specific processes and procedures implemented by KUS Pre-cast Concrete to integrate the HIRARC framework within their concrete work activities. It will highlight the company's efforts in hazard identification, risk assessment, and risk control, as well as the training and communication strategies employed to ensure HIRARC awareness among employees.
9 Figure 4: Factory layout and Production Layout By studying KUS Pre-cast Concrete (M) Sdn Bhd's background in relation to HIRARC, we can gain valuable insights into the company's commitment to safety, their risk management practices, and the successful integration of the HIRARC framework in the concrete work processes.
10 3. FACTOR IN THE ACTIVITIES THAT MAY CAUSE INJURIES OR ACCIDENTS 3.1 BATCHING AND CASTING PROCESS a. Dust from sand and aggregates during batching operation. b. Untrained/ not competent driver concrete truck. c. Overload concrete on cement truck. d. Untrained/ not competent forklift operator. 3.2 CONCRETING AND VIBRATION PROCESS a. Narrow/ limited space on workspaces and walkways can cause slip and trip. b. Damage parts on vibrator machine can cause harm to workers and others. c. Concrete buckets fell and hit the worker. d. Noises on machine during vibration process e. 3D mold/ vibrator machine possibility can fall to ground during concreting.
11 1 2 3 ITEM Irritate eyes, nose, throat and the upper respiratory system Un-stable concrete truck and cause the truck to roll over and lead to an accident. Untrained/ not Concrete truck crashing competent driver. with other transporter Operator/ driver do not which can cause death follow speed limit that and injury while allow on site which can driving. cause an accident Overloaded concrete truck and irrresponsible P.I.C on calculation of the amount of concrete Dust from cement, sand and aggregates during batching operation Safety supervisor Production foreman Production Foreman/ driver & director Figure 5: Haze Figure 7: Un-stable Concrete Truck Mobile tank/ concrete Untrained/ not bucket fall onto competent forklift ground/ hit ground Manager operator worker. Forklift Figure 8: Concrete overturned to ground. Bucket Fall onto Ground Table 5: The incident batching and casting process. 3.3 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS BATCHING AND CASTING PROCESS. P.I.C ACCIDENT/ EXAMPLE TYPE OF ACCIDENTS ROOT CAUSE RESPONSIBLE PICTURE ON INCIDENT 4 Figure 6: Concrete Truck Crashing
12 1 2 3 ITEM TYPE OF ACCIDENTS ROOT CAUSE Narrow/ Wet surfaces/ Worker slip and trip on limited space and workspaces/ walkways. material/ machinery is not organized. Vibration transmitted into workers hands and arms when using hand held vibration machinery. Excessive Damage parts on poker exposure can affect the vibrator machine and nerves, blood vessels, no inspection/ services muscles and joints of before work start. the hand, wrist and arm causing Hand-Arm Vibration Syndrome (HAVS). Damage hook block and Concrete bucket wire rope. No prefalling/slipping from inspection and services overhead hoists. before casting. Manager Foreman Manager, foreman & director P.I.C RESPONSIBLE ON INCIDENT 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS. Figure 11: Concrete bucket falling. Figure 10: Vibration transmitted into workers hands and arms Figure 9: Worker Slip on Workspaces ACCIDENT/ EXAMPLE PICTURE
13 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS (CONT’). 3.5 ACCIDENT PREVENTION 3.5.1 ACCIDENT PREVENTION FOR BATCHING AND CASTING PROCESS a. Irritate eyes, nose, throat, and the upper respiratory system. We need to provide Personal Protective Equipment (PPE). Provide appropriate personal protective equipment to workers based on the nature of the irritants present. This may include respiratory protection, such as masks or respirators, as well as eye protection, gloves or protective clothing. Train workers on the correct use, maintenance, and limitations of PPE. Figure 12: Hearing loss. Figure 13: Concrete mould 3D broken. Table 6: The incident concreting and vibrating process. 4 .5 Concrete mould (3D mould) damage/ broken/ fall to ground during concreting. Physical hazard such as Noises on machine permanent tinnitus and/or during vibration hearing loss. process. Over vibration, Manager, overloaded concrete foreman & and damage jointing on director concrete mould. Manager and foreman ITEM TYPE OF ACCIDENTS ROOT CAUSE P.I.C RESPONSIBLE ON INCIDENT ACCIDENT/ EXAMPLE PICTURE
14 b. Concrete truck crashing with other transporter which can cause death and injury while driving. We must provide driver training and qualifications to ensure that concrete truck drivers are properly trained and licensed for operating large vehicles. Provide comprehensive training that includes defensive driving techniques, awareness of blind spots, and the specific handling characteristics of concrete trucks. Also, we regularly need vehicle maintenance. Implement a regular maintenance program for concrete trucks to ensure they in good working condition. Conduct inspections and address any mechanical issues promptly. Pay attention to brakes, tires, suspension and other critical components that can affect the vehicle’s performance. c. Un-stable concrete truck and cause the truck to roll over and lead to an accident. At this point, we need to have Vehicle Stability Control Systems. Consider equipping concrete trucks with stability control systems, such as electronic stability control (ESC) or rollover stability systems (RSS). These systems can help detect and correct potential instability before it leads to a rollover. Besides that, instruct drivers to avoid sharp turns or sudden maneuvers that can destabilize the concrete truck. Encourage them to navigate curves and corners at safe speeds, considering the load’s momentum. Lastly, develop a route planning strategy that considers road conditions, clearance heights, and potential hazards such as steep inclines or uneven surfaces. Identify routes that minimize the risk of rollovers and ensure drivers are aware of any potential challenges along their designated routes.
15 We need to access and monitor vibration levels. Before using any handheld vibrating tool, conduct a risk assessment to determine the vibration levels they produce. Consult the tool manufacturer’s 3.5.2 ACCIDENT PREVENTION FOR CONCRETING AND VIBRATING PROCESS a. Slips, Trips and Falls. Concrete work often involves wet surfaces, so implement measures to prevent slips, trips, and falls. Use anti-slip coatings on walkways and platform, provide proper drainage to remove excess water and use barricades or warning signs to indicate slippery area. Moreover, ensure that workspaces and walkways are kept free of clutter, debris, and obstacles. Regularly inspect and clean the area to remove any hazard that could cause slips, such as water, oil, or other liquids. b. Workers are exposed to vibration transmitted through handheld tools or equipment it can lead to hand arm vibration syndrome (HAVS). d. Mobile tank/ concrete bucket fall onto ground/ hit ground worker. Forklift overturned to ground. We must have load management and securement. Properly manage and secure the loads carried by mobile tanks, concrete buckets, and forklifts. Follow load capacity limits and distribute the weight evenly to maintain stability. Use appropriate restraints, such as straps or chains, to secure the loads and prevent shifting during transport. Moreover, we need to implement fall protection measures for workers who are working at heights or in proximity to mobile tanks, concrete buckets, or forklifts. Provide appropriate personal protective equipment, such as safety harnesses, and establish procedures for trying off and working safely at elevated locations.
16 c. Concrete bucket falling/slipping from overhead hoists. specifications or use vibration measurement devices to ensure compliance with safety standards. Regularly monitor and review vibration exposure level to identify potential hazards. Secondly, provide training and information. Train workers on the risks associated with hand-arm vibration and educate them about safe work practices. Ensure they understand how to properly grips tools and equipment to minimize vibration exposure. Provide information on early symptoms of HAVS and the importance of reporting any discomfort or symptoms promptly. Lastly, we can implement work rotation and breaks. Limit the duration of exposure to vibrating tools by implementing work rotation schedules. Regularly rotate workers to different tasks that do not involve vibration exposure. Provide frequent breaks to allow workers’ hands and arms to rest and recover from vibration. We must inspect concrete buckets regularly for any signs of damage, such as cracks, worn-out hooks, or weakened handles. Ensure that the buckets are in good condition and meet the necessary safety standards before use. Next, we need to have Standard Operating Procedures (SOP) for safe loading and unloading. Establish safe procedures for loading and unloading concrete buckets onto the hoisting equipment. Use designated loading areas and ensure that workers stand clear during the process. Avoid overloading the buckets beyond their capacity to maintain stability. Finally, we need to secure attachment points. Make sure that the attachment points between the concrete bucket and the hoisting equipment are properly secured. Use appropriate rigging techniques, such as using reliable hooks, slings, or clamps to prevent accidental detachment or slipping.
17 1. No ConsequenActivity Hazard ess Batching Untrained/ not -Accident & Casting competent Injury/deat process driver (cement h truck/forklift) Existing Control (if any) -In-house initial induction training is provided. -Limit the use of cement truck only to competent driver Likell hood (L) 1 Sever -ity (S) 3 d. Concrete 3D mold damage/ broken/ fall to ground during concreting. We must have proper mold design and construction. Ensure that the concrete molds are designed and constructed to withstand the weight and pressure of the concrete, use durable materials and reinforcement, such as steel or high-strength plastics, that can handle the concrete’s forces without breaking or deforming. Not only that but also, we need to regularly inspect and maintenance the concrete 3D mold. Conduct routine inspections of the mold to check for any signs of wear, damage, or weaknesses. Inspect the connections, hinges, latches, and other components to ensure they are in good working condition. Recommen Risk d-ation Low -Refreshment training for cement truck time to time. Produc -tion Foreman Respo n-sible Party 3.6 HAZARD HAZARD IDENTIFICATION RISK ASSESSMENT RISK CONTROL
18 2. Manual Handling of heavy/ big size of mould Narrow/ limited space Manual Handling of heavy big size of mould -Work related Musculo sketetal -Work related Musculo skeletal disorder (WMSD) -Traffic disruption ConcretinNoise from the -Noise -g & machine Induced Vibration Hearing Process Loss (NIHL) -Hit pedestrian/ ground worker -Good housekeep -ing -Practice two-man work system to -Park in designated parking area -Practice two-man work system to assist heavy material handling -Not available 2 2 3 3 3 2 1 1 1 2 Low Low Low Low Low -Continue current Practice -Provide suitable PHP based on NRA recommend ation. -Continue current practice -Set the speed limit for cement truck on site. -Appoint another ground workers as signalman if necessary -Continue current practice Produc -tion Foreman Produc -tion Foreman Produc -tion Foreman Produc -tion Foreman Produc -tion Foreman
19 Narrow/limite - d Space disorder (WMSD) Slip and trip assist heavy material handling -Housekee -ping 3 1 Low Table 7: Hazard Identification, Risk Assessment & Risk Control (HIRARC) in Concrete Works Working with concrete can be a hazardous activity. With the proper procedures, PPE, training, equipment, communication, maintenance, guarding, and effective management of the mobile equipment and human interface, it can be done safely. Conclusion on major Safety Concerns for Concrete Workers. Available at : https://www.safeopedia.com/major-safety-concerns-for-concreteworkers-and-what-to-do-about-them/2/6066 ( Accessed : 24 May 2023). Guideline for Hazard Identification, Risk Assessment and Risk Control (HIRARC). (2008) Available at : https://www.dosh.gov.my/index.php/legislation/guidelines/hirarc2/1846-01-guidelines-for-hazard-identification-risk-assessment-and-riskcontrol-hirarc-2008/file (Accessed : 28 May 2023). Concrete Construction Hazards and Our Solution From OSHA. Available at : https://concretesupplyco.com/hazards-solutionsosha/#:~:text=If%20you%20or%20your%20crew,long%20sleeves%20while %20on%20site. (Accessed : 26 May 2023). -Regulary housekeep -ing Produc -tion Foreman 5. REFERENCES 4. DISCUSSION AND CONCLUSION
TABLE OF CONTENTS 1 INTRODUCTION.......................................................1 1.1 HAZARD IDENTIFICATION AND RISK ASSESSMENT ...............1 1.2 PURPOSE OF HIRARC ...............................................2 1.3 TERM AND DEFINITIONS............................................2 1.4 HIRARC ACTIVITY PLANNING ......................................3 1.5 PROCESS OF HIRARC ...............................................3 1.5.1 WORKPLACE HAZARAD IDENTIFICATION ......................4 1.6 RISK ASSESSMENT...................................................5 1.6.1 LIKELIHOOD.......................................................5 1.6.2 SEVERITY..........................................................5 1.6.3 TABLE OF RISK....................................................6 2 BACKGROUND OF CASE STUDY ....................................7 2.1 LOCATION OF CASE STUDY ........................................7 2.2 ABOUT OF CASE STUDY ............................................8 3. FACTOR IN THE ACTIVITIES THAT MAY CAUSE INJURIES OR ACCIDENTS .............................................................10 3.1 BATCHING & CASTING PROCESS ..................................10 3.2 CONCRETING & VIBRATION PROCESS ............................10 3.3 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS BATCHING AND CASTING PROCESS ......................................................11 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS .................................................................12 3.5 ACCIDENT PREVENTION............................................13 3.5.1 ACCIDENT PREVENTION FOR BATCHING AND CASTING PROCESS ......................................................13 3.5.2 ACCIDENT PREVENTION FOR CONCRETING AND VIBRATING PROCESS .................................................................15 3.6 HAZARD..............................................................17 4. DISCUSSION AND CONCLUSION ...................................19 5. REFERENCES.........................................................19
LIST OF FIGURES FIGURE 1: FLOWCHAT OF HIRARC.....................................4 FIGURE 2: LOGO OF KUS PRE-CAST CONCRETE SDN BHD...........7 FIGURE 3: LOCATION OF PRODUCTION FACTORY ...................7 FIGURE 4: FACTORY LAYOUT AND PRODUCTION LAYOUT..........8 FIGURE 5: PRE-CONCRETE PRODUCTION USING MOULD ...........8 FIGURE 6: HAZE .........................................................11 FIGURE 7: CONCRETE TRUCK CRASHING .............................11 FIGURE 8: UN-STABLE CONCRETE TRUCK ............................11 FIGURE 9: CONCRETE BUCKET FALL ONTO GROUND ...............11 FIGURE 10: WORKER SLIP ON WORKSPACES .........................12 FIGURE 11: VIBRATION TRANSMITTED INTO WORKERS HANDS AND ARMS ................................................................12 FIGURE 12: CONCRETE BUCKET FALLING ............................12 FIGURE 13: HEARING LOSS .............................................13 FIGURE 14: CONCRETE MOULD 3D BROKEN ..........................14 LIST OF TABLES TABLE 1: THE VALUE OF LIKELIHOOD.................................5 TABLE 2: THE SEVERITY VALUE........................................6 TABLE 3: THE MAGNITUDE OF THE RISK LEVEL ......................6 TABLE 4: THE RELATIVE RISK LEVEL ..................................6 TABLE 5: THE INCIDENT BATCHING AND CASTING PROCESS .......11 TABLE 6: THE INCIDENT CONCRETING AND VIBRATING PROCESS .12 TABLE 7: HAZARD IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL (HIRARC) IN CONCRETE WORK.......................17
1 1.INTRODUCTION In recent years, Hazard Identification, Risk Assessment and Risk Control (HIRARC) has become the basis of business planning, management, and operational practices as the basis of risk management. When conducting a workplace risk assessment many changes in work practices on site will be observed. With HIRARC, one will be able to identify hazards, analyse and assess relevant risks and then apply appropriate control measures. 1.1 HAZARD IDENTIFICATION AND RISK ASSESSMENT WILL HELP YOU: a. Identify and control workplace hazards. b. Create awareness among employees – and use it as a training tool. c. Establish risk management standards based on acceptable safe practices and legal requirements. d. Reduce workplace incidents. e. Save costs by being proactive instead of reactive. f. Effective management controls will raise the standard of health and safety measures. People often think that incidents happen because of employee negligence or mistakes. However, most workplace incidents occur due to inadequate management controls.
2 1.2 PURPOSE OF HIRARC a. To identify all the factors that may cause harm to employees and others (the hazards). b. To consider what the chances are of that harm actually be falling anyone in the circumstances of a particular case and the possible severity that could come from it (the risks) c. To enable employers to plan, introduce and monitor preventive measures to ensure that risks are adequately always controlled. 1.3 TERM AND DEFINITIONS I. Hazard - A source or a situation with a potential for harm in terms of human injury or ill health, damage to property, damage to the environment or a combination of these. II. Hazard control - The process of implementing measures to reduce the risk associated with a hazard. III. Hierarchy of control - The established priority order for the types of measures to be used to control risks. IV. Hazard identification - The identification of undesired events that lead to the materialisation of the hazard and the mechanism by which those undesired events could occur. V. Risk - A combination of the likelihood of an occurrence of a hazardous event with specified period or in specified circumstances and the severity of injury or damage to the health of people, property, environment or any combination of these caused by the event.
3 VI. Risk assessment - The process of evaluating the risks to safety and health arising from hazards at work. VII. Risk management - The total procedure associated with identifying a hazard, assessing the risk, putting in place control measures, and reviewing the outcomes. 1.4 HIRARC ACTIVITY PLANNING HIRARC activities should be planned and carried out for situations where the hazard appears to pose a significant threat, or it is uncertain whether existing controls are adequate and before implementing corrective or preventive measures. HIRARC activities are also planned and managed by organizations that intend to continuously improve the Health and Safety Management System. It should be the duty of the employer to assign trained personnel to lead a team of employees related to a particular process or activity to carry out HIRARC. 1.5 PROCESS OF HIRARC Process of HIRARC requires 4 steps - a. Classify work activities b. Identify hazard c. Conduct risk assessment (analyse and estimate risk from each hazard), by calculating or estimating - i. likelihood of occurrence ii. severity of hazard d. Decide if risk is tolerable and apply control measures (if necessary).
4 1.5.1 Workplace Hazard Identification To highlight the critical operations of tasks, that is those posing significant risks to health and safety of employees as well as highlighting those hazards pertaining to certain equipment due to energy sources, working conditions or activities performed. Hazard can be divided into three main groups, health hazards, safety hazards and environmental hazards. a) Occupational Health Hazard is any agent can cause illness to an individual. b) Safety Hazard is any force strong enough to cause injury or damage to property. c) Environmental Hazard is a release to the environment that may cause harm or deleterious effects. Figure 1 : Flowchart of HIRARC
5 1.6 RISK ASSESSMENT 1.6.1 Likelihood The likelihood of the risk will be based how often the hazard will occur. The value of the likelihood is based on: LIKELIHOOD JUSTIFICATION RATING Most Likely Highly will happen or have happen before. 5 Possible Have a chance will happen and it’s not impossible. 4 Conceivable Maybe will happen with any additional factor. 3 Remote Still not clear about situation after several operation. 2 Inconceivable It’s unbelievable incident or never happened before or never recorded it’s has happened before. 1 Table 1: The value of likelihood. 1.6.2 Severity Severity can be determined based on the effect of the hazard to safety and health of the workers. This also includes the lost cost of company property if the accident happened. The severity value based on: SEVERITY JUSTIFICATION RATING Catastrophic Numerous fatalities, irrecoverable property damage and productivity. 5 Fatal Approximately one single fatality major property damage if hazard is realized. 4 Serious Non-fatal injury, permanent disability. 3 Minor Disabling but not permanent injury. 2 Negligible Minor abrasions, bruises, cuts, first aid type injury. 1 Table 2: The severity value.
6 1.6.3 Table of Risk The table of risk will be used after the severity and likelihood of the hazard was done. This will show the magnitude of the risk level. Severity Likelihood 1 2 3 4 5 5 5 10 15 20 25 4 4 8 12 16 20 3 3 6 9 12 15 2 2 4 6 8 10 1 1 2 3 4 5 Table 3: The magnitude of the risk level. High Medium Low The relative risk level can be used to prioritise necessary actions to effectively manage workplace hazards. Table below determines priority based on the following ranges: Risk Level Action High A HIGH risk requires immediate action to control the hazard as detailed in the hierarchy of control. Actions taken must be documented on the risk assessment from including date for completion. Medium A MEDIUM risk requires a planned approach to control the hazard and applies temporary measures if required. Actions taken must be documented on the risk assessment from including date for completion Low A risk identified as LOW may be considered as acceptable and further reduction may not be necessary. However, if the risk can be resolved quickly and efficiently, control measures should be implemented and recorded. Table 4: The relative risk level.
7 2. BACKGROUND OF CASE STUDY 2.1 LOCATION OF CASE STUDY This report focuses on the implementation of the HIRARC (Hazard Identification, Risk Assessment, and Risk Control) framework in the context of concrete work at KUS Pre-cast Concrete (M) Sdn Bhd. KUS Precast Concrete is a prominent company based in Ulu Tiram, Johor, Malaysia, specializing in the production of precast concrete products. With a strong commitment to workplace safety and health, the company has embraced the HIRARC framework to effectively manage hazards, assess risks, and implement control measures. Figure 2: Logo of KUS Pre-cast Concrete Sdn Bhd Figure 3: Location of Production Factory
8 2.2 ABOUT OF CASE STUDY KUS Pre-cast Concrete (M) Sdn Bhd has established itself as a leader in the precast concrete industry, providing innovative and high-quality solutions for various construction projects. The company has built a solid reputation based on its expertise, state-of-the-art facilities, and commitment to delivering durable and sustainable precast concrete products. In line with its dedication to safety, KUS Pre-cast Concrete recognizes the importance of implementing comprehensive risk management practices. The HIRARC framework serves as a cornerstone of the company's approach, allowing them to proactively identify potential hazards, evaluate associated risks, and implement appropriate control measures to ensure the safety and well-being of their workforce. This report explores the background and practices of KUS Pre-cast Concrete (M) Sdn Bhd in relation to HIRARC and its application to concrete work. It examines the company's commitment to safety, including their organizational structure, key personnel responsible for health and safety, and the initiatives in place to promote a culture of risk management and continuous improvement. Furthermore, this report will delve into the specific processes and procedures implemented by KUS Pre-cast Concrete to integrate the HIRARC framework within their concrete work activities. It will highlight the company's efforts in hazard identification, risk assessment, and risk control, as well as the training and communication strategies employed to ensure HIRARC awareness among employees.
9 By studying KUS Pre-cast Concrete (M) Sdn Bhd's background in relation to HIRARC, we can gain valuable insights into the company's commitment to safety, their risk management practices, and the successful integration of the HIRARC framework in the concrete work processes. Figure 4: Factory layout and Production Layout Figure 5: Pre-cast Concrete Production using mould.
10 3. FACTOR IN THE ACTIVITIES THAT MAY CAUSE INJURIES OR ACCIDENTS 3.1 BATCHING AND CASTING PROCESS a. Dust from sand and aggregates during batching operation. b. Untrained/ not competent driver concrete truck. c. Overload concrete on cement truck. d. Untrained/ not competent forklift operator. 3.2 CONCRETING AND VIBRATION PROCESS a. Narrow/ limited space on workspaces and walkways can cause slip and trip. b. Damage parts on vibrator machine can cause harm to workers and others. c. Concrete buckets fell and hit the worker. d. Noises on machine during vibration process e. 3D mold/ vibrator machine possibility can fall to ground during concreting.
11 3.3 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS BATCHING AND CASTING PROCESS. Table 5: The incident batching and casting process. ITEM TYPE OF ACCIDENTS ROOT CAUSE P.I.C RESPONSIBLE ON INCIDENT ACCIDENT/ EXAMPLE PICTURE 1 Irritate eyes, nose, throat and the upper respiratory system Dust from cement, sand and aggregates during batching operation Safety supervisor Figure 6: Haze 2 Concrete truck crashing with other transporter which can cause death and injury while driving. Untrained/ not competent driver. Operator/ driver do not follow speed limit that allow on site which can cause an accident Production Foreman/ driver & director Figure 7: Concrete Truck Crashing 3 Un-stable concrete truck and cause the truck to roll over and lead to an accident. Overloaded concrete truck and irrresponsible P.I.C on calculation of the amount of concrete Production foreman Figure 8: Un-stable Concrete Truck 4 Mobile tank/ concrete bucket fall onto ground/ hit ground worker. Forklift overturned to ground. Untrained/ not competent forklift operator Manager Figure 9: Concrete Bucket Fall onto Ground
12 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS. ITEM TYPE OF ACCIDENTS ROOT CAUSE P.I.C RESPONSIBLE ON INCIDENT ACCIDENT/ EXAMPLE PICTURE 1 Worker slip and trip on workspaces/ walkways. Narrow/ Wet surfaces/ limited space and material/ machinery is not organized. Manager Figure 10: Worker Slip on Workspaces 2 Vibration transmitted into workers hands and arms when using hand held vibration machinery. Excessive exposure can affect the nerves, blood vessels, muscles and joints of the hand, wrist and arm causing Hand-Arm Vibration Syndrome (HAVS). Damage parts on poker vibrator machine and no inspection/ services before work start. Manager, foreman & director Figure 11: Vibration transmitted into workers hands and arms 3 Concrete bucket falling/slipping from overhead hoists. Damage hook block and wire rope. No preinspection and services before casting. Foreman Figure 12: Concrete bucket falling.
13 3.4 THE ROOT CAUSE OF THE ACCIDENTS AND WHO SHOULD BE RESPONSIBLE FOR THAT INCIDENTS CONCRETING AND VIBRATION PROCESS (CONT’). Table 6: The incident concreting and vibrating process. 3.5 ACCIDENT PREVENTION 3.5.1 ACCIDENT PREVENTION FOR BATCHING AND CASTING PROCESS a. Irritate eyes, nose, throat, and the upper respiratory system. We need to provide Personal Protective Equipment (PPE). Provide appropriate personal protective equipment to workers based on the nature of the irritants present. This may include respiratory protection, such as masks or respirators, as well as eye protection, gloves or protective clothing. Train workers on the correct use, maintenance, and limitations of PPE. ITEM TYPE OF ACCIDENTS ROOT CAUSE P.I.C RESPONSIBLE ON INCIDENT ACCIDENT/ EXAMPLE PICTURE 4 Physical hazard such as permanent tinnitus and/or hearing loss. Noises on machine during vibration process. Manager and foreman Figure 13: Hearing loss. .5 Concrete mould (3D mould) damage/ broken/ fall to ground during concreting. Over vibration, overloaded concrete and damage jointing on concrete mould. Manager, foreman & director Figure 14: Concrete mould 3D broken.
14 b. Concrete truck crashing with other transporter which can cause death and injury while driving. We must provide driver training and qualifications to ensure that concrete truck drivers are properly trained and licensed for operating large vehicles. Provide comprehensive training that includes defensive driving techniques, awareness of blind spots, and the specific handling characteristics of concrete trucks. Also, we regularly need vehicle maintenance. Implement a regular maintenance program for concrete trucks to ensure they in good working condition. Conduct inspections and address any mechanical issues promptly. Pay attention to brakes, tires, suspension and other critical components that can affect the vehicle’s performance. c. Un-stable concrete truck and cause the truck to roll over and lead to an accident. At this point, we need to have Vehicle Stability Control Systems. Consider equipping concrete trucks with stability control systems, such as electronic stability control (ESC) or rollover stability systems (RSS). These systems can help detect and correct potential instability before it leads to a rollover. Besides that, instruct drivers to avoid sharp turns or sudden maneuvers that can destabilize the concrete truck. Encourage them to navigate curves and corners at safe speeds, considering the load’s momentum. Lastly, develop a route planning strategy that considers road conditions, clearance heights, and potential hazards such as steep inclines or uneven surfaces. Identify routes that minimize the risk of rollovers and ensure drivers are aware of any potential challenges along their designated routes.
15 d. Mobile tank/ concrete bucket fall onto ground/ hit ground worker. Forklift overturned to ground. We must have load management and securement. Properly manage and secure the loads carried by mobile tanks, concrete buckets, and forklifts. Follow load capacity limits and distribute the weight evenly to maintain stability. Use appropriate restraints, such as straps or chains, to secure the loads and prevent shifting during transport. Moreover, we need to implement fall protection measures for workers who are working at heights or in proximity to mobile tanks, concrete buckets, or forklifts. Provide appropriate personal protective equipment, such as safety harnesses, and establish procedures for trying off and working safely at elevated locations. 3.5.2 ACCIDENT PREVENTION FOR CONCRETING AND VIBRATING PROCESS a. Slips, Trips and Falls. Concrete work often involves wet surfaces, so implement measures to prevent slips, trips, and falls. Use anti-slip coatings on walkways and platform, provide proper drainage to remove excess water and use barricades or warning signs to indicate slippery area. Moreover, ensure that workspaces and walkways are kept free of clutter, debris, and obstacles. Regularly inspect and clean the area to remove any hazard that could cause slips, such as water, oil, or other liquids. b. Workers are exposed to vibration transmitted through handheld tools or equipment it can lead to hand arm vibration syndrome (HAVS). We need to access and monitor vibration levels. Before using any handheld vibrating tool, conduct a risk assessment to determine the vibration levels they produce. Consult the tool manufacturer’s
16 specifications or use vibration measurement devices to ensure compliance with safety standards. Regularly monitor and review vibration exposure level to identify potential hazards. Secondly, provide training and information. Train workers on the risks associated with hand-arm vibration and educate them about safe work practices. Ensure they understand how to properly grips tools and equipment to minimize vibration exposure. Provide information on early symptoms of HAVS and the importance of reporting any discomfort or symptoms promptly. Lastly, we can implement work rotation and breaks. Limit the duration of exposure to vibrating tools by implementing work rotation schedules. Regularly rotate workers to different tasks that do not involve vibration exposure. Provide frequent breaks to allow workers’ hands and arms to rest and recover from vibration. c. Concrete bucket falling/slipping from overhead hoists. We must inspect concrete buckets regularly for any signs of damage, such as cracks, worn-out hooks, or weakened handles. Ensure that the buckets are in good condition and meet the necessary safety standards before use. Next, we need to have Standard Operating Procedures (SOP) for safe loading and unloading. Establish safe procedures for loading and unloading concrete buckets onto the hoisting equipment. Use designated loading areas and ensure that workers stand clear during the process. Avoid overloading the buckets beyond their capacity to maintain stability. Finally, we need to secure attachment points. Make sure that the attachment points between the concrete bucket and the hoisting equipment are properly secured. Use appropriate rigging techniques, such as using reliable hooks, slings, or clamps to prevent accidental detachment or slipping.
17 d. Concrete 3D mold damage/ broken/ fall to ground during concreting. We must have proper mold design and construction. Ensure that the concrete molds are designed and constructed to withstand the weight and pressure of the concrete, use durable materials and reinforcement, such as steel or high-strength plastics, that can handle the concrete’s forces without breaking or deforming. Not only that but also, we need to regularly inspect and maintenance the concrete 3D mold. Conduct routine inspections of the mold to check for any signs of wear, damage, or weaknesses. Inspect the connections, hinges, latches, and other components to ensure they are in good working condition. 3.6 HAZARD No HAZARD IDENTIFICATION RISK ASSESSMENT RISK CONTROL Respo n-sible Party Activity Hazard Consequeness Existing Control (if any) Likell hood (L) Sever -ity (S) Risk Recommen d-ation 1. Batching & Casting process Untrained/ not competent driver (cement truck/forklift) -Accident Injury/deat h -In-house initial induction training is provided. -Limit the use of cement truck only to competent driver 1 3 Low -Refreshment training for cement truck time to time. Produc -tion Foreman
18 Narrow/ limited space -Hit pedestrian/ ground worker -Good housekeep -ing 2 2 Low -Set the speed limit for cement truck on site. -Appoint another ground workers as signalman if necessary Produc -tion Foreman -Traffic disruption -Park in designated parking area 2 2 Low -Continue current practice Produc -tion Foreman Manual Handling of heavy/ big size of mould -Work related Musculo skeletal disorder (WMSD) -Practice two-man work system to assist heavy material handling 3 1 Low -Continue current Practice Produc -tion Foreman 2. Concretin -g & Vibration Process Noise from the machine -Noise Induced Hearing Loss (NIHL) -Not available 3 1 Low -Provide suitable PHP based on NRA recommend ation. Produc -tion Foreman Manual Handling of heavy big size of mould -Work related Musculo sketetal -Practice two-man work system to 3 1 Low -Continue current practice Produc -tion Foreman
19 disorder (WMSD) assist heavy material handling Narrow/limited Space Slip and trip -Housekee -ping 3 1 Low -Regulary housekeep -ing Produc -tion Foreman Table 7: Hazard Identification, Risk Assessment & Risk Control (HIRARC) in Concrete Works 4. DISCUSSION AND CONCLUSION Working with concrete can be a hazardous activity. With the proper procedures, PPE, training, equipment, communication, maintenance, guarding, and effective management of the mobile equipment and human interface, it can be done safely. 5. REFERENCES Conclusion on major Safety Concerns for Concrete Workers. Available at : https://www.safeopedia.com/major-safety-concerns-for-concreteworkers-and-what-to-do-about-them/2/6066 ( Accessed : 24 May 2023). Guideline for Hazard Identification, Risk Assessment and Risk Control (HIRARC). (2008) Available at : https://www.dosh.gov.my/index.php/legislation/guidelines/hirarc2/1846-01-guidelines-for-hazard-identification-risk-assessment-and-riskcontrol-hirarc-2008/file (Accessed : 28 May 2023). Concrete Construction Hazards and Our Solution From OSHA. Available at : https://concretesupplyco.com/hazards-solutionsosha/#:~:text=If%20you%20or%20your%20crew,long%20sleeves%20while %20on%20site. (Accessed : 26 May 2023).