CONSTRUCTION SAFETY

A ISO 9001: 2015 Organization

Construction Safety

• No adjustment may be made to any guard while cutters are in motion, unless safe means (i.e.
mechanical adjusters) are provided.

• Allowance can be made for the development of alternative safeguards for cutters provided these
are effective.

• All moving parts, other than cutters, must be guarded.

CIRCULAR SAW

Riving Knife (Splitter or Spreader)

 Securely fixed below machine table level, behind and in line with saw blade. Must be strong,
rigid, smooth and easily adjustable.

 Radius of knife not to exceed radius of largest saw blade for which machine is designed.

 Adjusted as close as practicable to saw blade; gap between knife and blade not to exceed 12
mm at table level.

 In the case of a parallel plate saw blade, the knife must be thicker (usually about 10%) than
the plate of the saw blade.

 Where the diameter of the saw blade is less than 600mm, the top of the knife should not be
more than 25mm below the top of the blade. Knife must extend at least 225mm above the
table.

Top Guard (Crown Guard)

Guard to be strong and easily adjustable. It should be adjusted to extend from top of riving knife to
a point as close as practicable to the surface of the material being cut, or, to a point not more than
12mm above the material being cut where squared stock is being hand fed. The guard should have
flanges on either side of the blade and be adjusted so that these extend beyond the roots of saw
teeth. Where the guard has an adjustable front extension piece, it must be flanged on the
side remote from the fence, and adjusted to extend beyond the roots of saw blade teeth.

Size of saw blade

• saw benches with a one-speed spindle must not use a saw blade less, than 60% of the diameter

of the largest saw blade the bench is designed to use,

• in the case of saw benches with more than one spindle speed, the blade must not be less than

60% of the diameter of the largest blade the machine is designed to use at fastest spindle speed,

• A notice must be displayed on the machine specifying the smallest diameter saw blade to be used

in compliance with the above provisions.

Limitations on use

 No circular saw may be used for cutting any rebate, tenon, moulding or groove unless the
cutter above the table is effectively guarded.

 The saw blade teeth must project right through the upper surface of the timber at all times in

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Construction Safety

any ripping operation.

 Circular saw must not be used for cross-cutting logs unless the material is firmly held by a
gripping device secured to a traveling table.

Push sticks must be available for use on every hand-fed circuit saw, and used to:

• feed material throughout any cut of 300mm or less.

• Feed material during the last 300mm of any cut more than 300mm in length.

• remove cut material from between the saw blade and the fence.
• Removal of material

• Assistants employed to 'take-off cut material may only stand at the delivery end of machine.

• where this operation must be performed, the delivery end of the machine table must extend (over

its whole width) at least 1200mm from the up-running part of saw blade.

HAND HELD POWER CIRCULAR SAWS

Modern machines are fitted with guards that completely enclose the saw blade; the depth of
cut is adjusted by altering the position of moveable shoe or plate in relation to the saw. For
bevel cutting, the shoe may be set at an angle to the plane of the saw.

Before using the saw, ensure that:
• Correct type of blade is used for the material to be cut.
• Blade is in good condition, not cracked or damaged
• Blade will rotate in the correct direction
• Depth of cut is adjusted so that the saw blade only just projects through the underside of 1 the

material being cut.

• Guard which covers the saw blade shoe is designed to retract as the blade enters the material.

• It must never be tied back or rendered inoperative during sawing.
• Guard operates freely before using the machine.
• On/off switch is in good working order.
• Material is properly supported before cutting.

CHAIN SAWS
All workers who use a chain saw should be competent to do so. The operator or worker should have
received appropriate training and obtained relevant certificates of competence.

It is recommended that all chain saw operators have regular refresher/updates training every 2- 3
years.

Preparing to Use a Chainsaw

Operators should check:

• All nuts and screws etc. are tight.

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• Saw chain is correctly tensioned

• Throttle cannot be squeezed unless throttle lock - out is pressed

• Operators are wearing the correct PPE.

When starting a chainsaw operation, place the saw on level ground; secure saw firmly, e.g. put a foot
on the rear handle base plate and a hand on the front handle; set the controls as recommended by
the manufacturer; and pull the starter cord firmly.

Training

No person should be employed on a woodworking machine, unless he has been trained and instructed
in its operation. Training should include

 Instruction on all machines the person is likely to operate and the types of work to be
undertaken on completion of training.

 Instruction on the provisions in the law on Woodworking machines and the methods of using
guards, devices and appliances required by the law must be included.

 emphasize the dangers connected with the use of such machines.

ABRASIVE WHEELS

Abrasive wheels are commonly used in the workshop environment, and are potentially dangerous
because of their high speed of rotation, with the resultant possibility of break - up under centrifugal
stress.

For these reasons it is paramount that all personnel who use abrasive wheels follow the rules set out
in this section, in especially the wearing of suitable and approved eye protection. Abrasive wheels are
defined as:

• Wheel, cylinder, disk or cone which, whether or not any other material is comprised therein,
consists of abrasive particles held together by mineral, metallic or organic bonds whether
natural or artificial.

• A mounted wheel or point and a wheel or disc having in either case separate segments of
abrasive material.

• A wheel, or disc made in either case of metal, wood, cloth, fell, rubber or paper and having
any surface consisting wholly or partly of abrasive material.

• A wheel; disc or saw to any surface any of which is attached a rim or segments consisting in
either case of diamond abrasive particles, which is, or is intended to be, power driven and is
for use in any grinding or cutting operations;

Duties of Operators

• No employed person using an abrasive wheel shall willfully misuse or remove any guard, or
misuse any protection flanges, other appliance provided, or any rest for a work piece.

• Every employee shall make full and proper use of guards, protection flanges and any other
safety devices fitted, and if he discovers any defect in the same, shall report such defect to
the manager, or other appropriate person.

Selection of Wheels

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When selecting a wheel, due account shall be taken of the factors which affect safety. Selecting the
correct wheel for the job is equally important for efficient production and for safety. As a rough and
ready rule, soft wheels are more suitable for hard material and hard wheels for soft material. The best
policy in selecting grinding plant is to consult Manufacturers of machines and abrasive wheels, and
not to experiment without competent advice.

Mounting of Wheels

Wheel speed: before mounting the wheel, check that the speed of the spindle does not exceed the
maximum permissible speed marked on the wheel, it must be remembered that centrifugal force (the
ultimate cause of wheel bursts) increase, not directly with speed, but as the square of the speed. The
speed at which the grinding wheel revolves is, therefore, extremely important, It cannot be too
strongly impressed that doubling the number of revolutions per minute of a wheel, increases four fold
its tendency to burst. The peripheral speed is generally used for describing permissible wheel.

Flanges: every abrasive wheel must be mounted between suitable flanges, which should be not less
than one third the diameter of the wheel. The flanges should be recessed on the side next to the
wheel, to ensure that clamping pressure is not exerted near the hole; flanges should be of mild steel
or other material of equal or greater strength and rigidity. Ordinary cast iron is not suitable

Washers

Washers or blotters, as they are sometimes called, should be made of compressible material not more
than 1/16th of an inch thick. They should be used between the wheel and the flanges whenever the
clamping surfaces are flat, but not otherwise, as in the instance of taper sided or dovetailed abrasive
wheels.

Starting new wheels

• Before running the wheel, make sure the guard is in proper adjustment.

• if the machine is fitted with a work rest, adjust this as close to possible to the surface of the
wheel, rotate the wheel by hand to make sure it is clear all the way round.

Unacceptable Practices

The following unacceptable practices increase the liability of the wheel to fracture because they result
in excessive stress concentrated. Near the hole:

 Paper washers not used between the wheel and the flanges.

 Flanges not recessed.

 Flanges unmatched in outside diameter and diameter of recess

 One flange omitted and the nut tightened directly against the whirl

 The use of an ordinary steel washer as a substitute for a properly recessed flange.

Cutting-off Wheels

 Only be mounted on machines designed especially for their use.
 Wheel must be of the reinforced type.

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Construction Safety

 Flanges should be as large as practicable and never less than one third of the wheel diameter.
It is most important that the flanges should be equal diameter.

 Use of unequal flanges is liable to cause distortion and breakage of a cutting-off wheel.

Pedestal/Bench Mounted Grinders

• Manufacturers safe operating and mounting procedure must be followed.
• check the rated speed of the machine and peripheral speed of the wheel labeled by the

manufacturer.

* Check for any crack or defect in the wheel.
* Tool rest must be provided and the gap between tool rest and wheel shall not exceed 1 /8th of an

inch.

* Apply only regulated pressure on wheel. Never take too heavy a cut.

* Allow wheel to run for a minute before starting grinding.

* Grinding must not be done at sides of wheel.

* Screen of toughened glass should be provided to protect operator’s eyes.

Guards For straight-sided wheels, the maximum angular exposure of the abrasive periphery and
• sides shall not exceed 180°°. Guards for straight grinding machines shall be provided with
a front curtain, which shall be securely fastened to the body of the machine.

• For depressed centre grinding wheels, the wheel shall have a maximum angular exposure
of 180° and the guard shall be located as to be between the operator and the wheel during
use.

• The clearance between the inside of the guard and the periphery of the unused wheel shall
be not greater than 5% of the nominal wheel diameter.

Controls

 Machines in which abrasive wheels are used must be provided with efficient devices for starting
and cutting off power, and the controls of such devices must be readily and conveniently
operated by the person using the machine.

 While the wheel is in motion, they must be properly secured and adjusted so as to be as close
as practicable to the exposed part of the abrasive wheel.

General Safety Requirements

Floors surrounding every fixed machine or area where portable tools are being used, shall be
maintained in good and even condition. So as far as practicable it will be kept clear of loose material
and prevented from becoming slippery.

Cautionary Notice

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An approved cautionary notice of the hazards arising from the use of abrasive wheels shall be affixed
in every room where grinding or cutting is carried out.

Eye protection

Persons carrying out dry grinding operations, truing or dressing an abrasive wheel, must wear suitable
eye protection, or be protected by suitable transparent screens.

MACHINERY

 When persons are required to work in elevated positions then they may be in close proximity
to dangerous parts of moving machined which would otherwise be safe by position. In such
cases, the machines must be locked off with the maintenance operator holding the key, and
the activity controlled by a "Permit to Work" system.

 Where it is necessary to keep any such machine working, then the maintenance should be re-
scheduled to a time when it is possible to close the machine down or, alternatively, protective
screens must be erected to prevent the risk of contact with the dangerous parts.

 Erection of such screening would take place with the machine locked off under a "Permit to
Work” system. Particular attention should be given to the situation where persons are required
to work on or near the wheel track of an overhead traveling crane, or any other position where
he can be struck by a part of that crane.

 The crane should either be locked off or have stops fitted to the rail to ensure that the crane
does no, approach within 6.0m of that person.

SAFE WAYS OF USING MECHANCAL EQUIPMENT

The safest way of using mechanical equipment is to have properly trained operators, operating the
equipment which is well maintained and operate only for which it is designed. The employer shall
comply with the manufacturer’s specifications and limitations applicable to the operation of any
mechanical equipment. It is important that, to do the work in a construction industry you must be
familiar with all the mechanical equipment used, their inspection and safe use.

General Requirements

Following are some of the general requirements for handling different mechanical equipments;

All machinery should be inspected before being placed in service and at regular intervals thereafter.

 No repair, adjustment, or replacement of parts on moving machinery is permitted. Before
making any repair, the equipment must be stopped and deactivated so that it cannot be
accidentally get started.

 At the start of each shift, the operator must check oil, water, fuel, and hydraulic levels, that
all gauges are operating and that the machine is functioning smoothly. Safety equipment (e.g.,
guards, limit switches) must be checked daily.

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Construction Safety

 Equipment travelling or working on the highway must have lights and reflectors. Park the
equipment away from the roadway. If this is not possible, use flashing lights, cones, or other
warning devices to alert approaching traffic.

 When vehicles are left unattended (even overnight), engines must be stopped, parking brakes
applied and the wheels chocked. Blades, scraper bowls, and other hydraulic equipment must
be lowered to the ground before the operator leaves the machine. The ignition key should be
removed and/or battery cables disconnected to avoid startup by unauthorized personnel.

 Cabs fitted to equipment must give 360° visibility. Cabs must be kept clean and clear of such
items as rubbish and loose tools.

 All equipment must be localized so that exhaust fumes will not affect workers in the area.
Gasoline-driven equipment shall not be used inside a building or other confined space.

Compressors
Compressors are one of the most common pieces of equipment used in construction work. They can
be used to supply air for portable power tools or to supply air to sustain men working with breathing
apparatus in extremely hazardous atmospheres. There is a considerable difference in the
quality of the air used for these two functions.

All employees on site must know the dangers of compressed air. Never use compressed air to dust
off clothing or machinery. When compressed air is used in special cleaning, goggles and full face shield
must be worn.
Compressors must be properly designed, inspected, tested and maintained. Relief valves shall be
installed and the air receiver must be periodically inspected.

Air compressor Before start up, a daily check should be made of the compressor’s pressure relief
valve, fuel, oil and water levels and the air reservoir should be drained of trapped water.

When compressors supply air for breathing;

 The air intake must be localized so that it does not draw in exhaust gas.
 There must be a filter to remove oil mist.
 They must be equipped with an automatic high temperature alarm.
 The air quality must be tested periodically to ascertain that it is safe to breathe.

Air Compressor

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Concrete Mixers and Batching Plants
A concrete mixer of certain type will be used on almost all construction site. The principles of good
maintenance and properly trained operators apply equally to avoid accidents and to maintain safety,
irrespective of the size of the mixer for masonry work.
All chains, gears, and revolving shafts must be guarded.
Safety chains and catches must be operative, and the lifting mechanism must be in good order.
Men must not be allowed to work under or near the loading skip unless it is held in position by a safety
chain.
The mixer drum and the area around the machine must be thoroughly cleaned at the end of each
day’s operation.
Cement bags must not be allowed to accumulate in the mixer area; they should be collected and
disposed of at regular intervals during the day.
The approach to the sand and aggregate bins should be barricaded, and the barricades should only
be removed to allow access for vehicles delivering materials.
Personal protective equipment such as respirators ear muffs and goggles shall be worn. Loose fitting
clothes shall not be worn around moving machinery.
Lockout and tag system is required in batching plants to ensure the safety of repair or maintenance
personnel. Lockout and tag system rules must be posted in a conspicuous location throughout the
plant and workers must be thoroughly trained in the lockout/tag procedures.

Dumpers and Dump Trucks

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Dumpers and dump trucks, commonly used for construction work, often travel on the public highway.
Therefore, it is essential that they should be properly maintained.
Dumpers are not designed to carry passengers. It is strictly forbidden for employees to ride in the
skip or on the engine cover.
When repairs or maintenance are being carried out on a hydraulically operated dump truck, the dump
body should be fully lowered. If it is necessary to have it in the raised position, it must be blocked.
Do not rely on the hydraulic ram to support the raised body for an extended Period. quipped with
windshields and powered wipers. Cracked or broken windshields or windows shall be replaced.

Excavators
Excavations are carried out using very specialized equipment which roughly falls into two categories:
1) fixed position machines, and
2) moving machines.
Fixed position machines include, but are not limited to, face shovels, backhoes, and grabs.
The “fixed” excavator loosens the soil and loads from a stationary position. They are useful to perform
specific excavation tasks at a single location. Their loss of mobility is compensated by the fact that
greater force can be applied at the excavation face.
‘'Moving" machines include, but are not limited to, bulldozers, loaders, scrapers, graders and trenching
machines. They remove, transport Excavator
and deposit excavated material all in one cycle of operation. They are used in applications where large
volumes of earth need to be moved over uneven ground. In this process, they also help to level the
ground over which they operate.

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Forklift Trucks
trucks are designed to operate on firm, level ground. This type of equipment has a limited use in
construction operations. They are, however, sometimes used in materials handling yards and for
placing loads where there are firm ground conditions. Before operating a fork lift it is important to
know the equipment and the load to be lifted. There are fork lift trucks of different types and
capacities. Training of the operators is important to avoid any accidents associated with fork lift
operation. Forklift steers from the rear and is less stable. Load and work site conditions are thus
important. Use seat belts, where a seat is provided, to avoid the chances of operator crushing under
the load in case of an accident. Forklift trucks may be of battery operated or with internal combustion
engines. The operator must make sure that the fork lift truck is in proper condition and the proper
inspections are to be conducted. The truck shall be equipped with overhead protection. When
travelling with a load on the forks, the forks should be as low as possible and the load should be taken
on forks as close as possible to the cabin to maintain stability. If the load being carried obstructs the
operator’s forward view, he should travel in reverse.

GENERATORS
A qualified electrician shall be available to ensure that electrical connections are properly made.
Fire Prevention Guide for Portable Generators
A thorough inspection must be made for

 Repair all fuel leaks.
 Check hose and pipe connections for wear and cracks.
 Clean up all combustible trash around the generator.
 Clean up all fuel spills around the area when required.
 Sheds constructed of combustible materials near generators and wooden base frames are

prohibited.
 Exhaust piping system shall be kept away from work areas and combustible materials.
 Generator sets shall be located at least 50 feet from buildings or materials that may catch fire.
 inspect all wiring for damage or improper splices/repairs.
 Electrically ground all generator sets (system and frame ground).
 Fire extinguishers must be readily accessible. One CO2 extinguisher for the generator and a

dry chemical extinguisher for the engine drive are recommended.

Conduct daily inspections of all generator sets using this guide.

Graders, Dozers, Scrapers, Loaders and Mini loaders

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Heavy earth moving equipment allows the operator a limited view of the area; therefore, it is essential
that a banks man be appointed to warn the operator of hazards that cannot be seen from the
operator’s position.
Before moving the machine, the driver must inspect the surrounding to see that the area is clear. Men
must not be allowed to sit or lie in the area around the machine.
The engine shall not be left running when the driver is not at the controls. Before leaving his machine,
the driver must shut off the engine and remove the ignition key.
Blades, scraper bowls, etc. must be lowered to the ground before the driver ieaves his unit. The
wheels should be properly chocked.

Woodworking Machinery
Adequately trained operators may be allowed to use woodworking machinery. The area around saws,
planers, and routers must be barricaded and only authorized and trained personnel allowed within the
barricaded area.

Cranes
Cranes consists of a rotating structure for lifting and lowering horizontally on rubber tyres or crawler
treads.

Terminology
 Hoist - Used to lift and lower load.
 Boom - An inclined spar, strut, or other long member supporting the hoisting tackle
 Boom stops - A device used to limit the angle of the boom at its highest position
 Brake - To slow or stop motion by friction or power
 Block - Sheaves or grooved pulleys in a frame with hook, eye and strap
 Job - Extension attached to the boom point to provide added boom length for lifting specified
loads.

Operation and Inspection of Cranes and Hoists

(a)General
All persons employed as operators of cranes and hoisting equipment will hold a provincial/
territorial/equivalent journeyman certificate of proficiency {or equivalent proof) in the operation of
cranes and hoists. The appropriate supervisor shall review the proficiency and knowledge of operators
when assigning work on specific equipment.

No worker shall operate a crane or similar hoisting device that is capable of raising, lowering or moving
material that weighs more than 7,260 kilograms unless the worker is certified as a hoisting engineer
under the Trades Qualification and Apprentice Act (or equivalent position in the prevailing jurisdiction).

(b) Inspections, Testing, and Logbooks
The owner of a crane or similar hoisting device shall keep a permanent record of the full history of all
inspections, tests, repairs, modifications and maintenance of each crane or hoisting device. These will
be made available upon request.
Each crane or hoisting device will be load tested, and will have all structural components including,
boom, hoist/hook assembly inspected and certified at least once in every twelve months by a quality
control company.

Each crane or hoisting device on the project site shall at all times have its own logbook that will include
all inspections, tests, repairs, modifications, rope changes, and maintenance for the immediate
preceding twelve months prior to first use at the site - and for the entire period that the crane or
hoisting device is on the site. No crane or hoisting device will be permitted on the project site without
such a logbook.

Cranes that enter and leave the project/ facility/ site on frequent short-term assignments will be
certified initially, and then after every six months thereafter. Whenever sudden and unusual shock

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loads are applied to a crane or hoisting device, it shall be removed from service immediately and shall
be subjected to complete inspection, testing and certification by a third-party agency prior to work.
All certifications shall be performed by a professional engineer authorized by law for the certification
of cranes, and who is registered in the province or region in which the project is located.

(c) Safety Devices
All cranes and hoists of 18-ton capacity and above shall have a load monitoring device installed to cut
hoisting power in the event of any overload condition. All cranes and hoists of 18-ton capacity and
above shall have an automatically engaged anti two-block device to prevent the hoisting block from
hitting the boom.

(d) Operation
The operator of a crane or hoisting device will:

 Familiarize him with the equipment and its proper care.
 Perform and log a “Daily Crane Safety Inspection” on electrical, pneumatic, cooling,

mechanical, hydraulic, suspension, structural, and safety devices on a daily or more frequent
basis in accordance with the manufacturer’s requirements.
 Test all controls at the start of each shift (if any function does not operate properly, they will
be repaired before any operations begin).
 Notify the next operator of any defects upon changing shifts.
 Be responsible for those operations under his direct control (whenever there is any doubt as
to safety, no operator will operate a crane until its safety has been assured).
 If there is a warning sign on the switch or engine starting controls, no person will close the
switch or start the engine until the warning sign has been removed by the person who place
there.
 Ensure that the weight of the load to be lifted is within the capacity of the machine.
 Not engage in any practice which will divert attention from the operation of the machine.
 Either have a clear and unrestricted view of the load and the operational area or act upon the
instruction of the appointed signalman/radioman.
 Do not hoist any equipment or load until safe working conditions have been assured, or orders
to proceed have been issued by the appointed signal man.
 Respond to signals only from the appointed signalman but obey a STOP signal at any time no
matter who gives it.
 Do not leave his position at the controls while a load is suspended.
 If power fails during operation, the operator will immediately set all brakes and locking devices,
and communicate with the individual in charge. If possible, a suspended load should be landed
under brake control.
 Before leaving his machine unattended, the operator will as far as practical: land any attached
load.
 Ensure that boom is not left suspended over operating plant.
 Tie back hook to the crane.
 Set all brakes and locking devices.
 Secure the unit against accidental travel and inadvertent movement.
 Lock doors to prevent unauthorized access.
 When a high wind warning is issued, the crane will be completely secured. If the cranes are
with hydraulic booms, the boom will be fully retracted.
 When lifting/moving loads the operator will ensure the load is kept under control at all times
and, where necessary, one or more guide ropes or tag lines will be used to prevent the rotation
or other uncontrolled motion of the load. The length of the tag line will be sufficient to ensure
that the worker controlling the tag line cannot be struck by any movement of the load.
 Ensure loads are not hoisted when uninvolved workers are within range of the fall envelope.

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 Ensure that (only) manufacturer’s lifting beams and are plainly marked with their weight and
designed working loads, or that they have an engineer’s certificate on file.

 Ensure that operators, riggers and supervisors are thoroughly familiar with the limitations of
the equipment.

Major Causes of Crane Accidents
Major causes of crane accidents are:

 Contact with power lines
 Overturns
 Falls
 Mechanical failures

Accidents also occur due to the following reasons:
 Instability - unsecured load, load capacity exceeded, or uneven ground or too soft.
 Lack of communication - the point of operation is at a distance from the crane operator or not
in full view of the operator
 Lack of training.
 Inadequate maintenance or inspection.

Crane Hazards
Following are the crane hazards which may become the reason for an accident,

 Improper load rating
 Excessive speeds
 No hand signals
 Inadequate inspection and maintenance
 Unguarded parts
 Unguarded swing radius
 Working too close to power lines
 Improper exhaust system
 Obstructed vision
 No steps / guardrails for walkways
 No boom angle indicator
 Not using outriggers

a) Improper Load Rating

Make sure that the crane operator can see the rated load capacities (the load which, under
different conditions the crane can hoist), operating speeds, and special warnings or
instructions.

The operator must know the weight of the load before lifting it. The weight of the load can be
obtained by referring the shipping tickets or other documents which will be available with the
load. Ensure the lift calculations are correct before lifting and the Joad is correct with the load
rating chart for boom length and load radius of crane. ' ;

Crane is rated by the maximum weight it will lift at a minimum radius and minimum boom
length the further from its center point, the less it will lift.

Following are the load limiting factors of a crane;
 Uneven surface
 Wind
 Side loads
 Crane lifting on its wheels
 Lifting over the side
 Use of extension's, jibs and other attachments

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 Limits of wire rope, slings and lifting devices

b) Hand Signals
Most of the time the operator may not be able to see the load from the operators’ cabin, but
the signal man will be standing clear to be visible to the operator. The absence of a signal man
during a lifting operation will result in an accident. Crane operator must always follow the
signals shown by the signal man.

Guard Moving Parts
The moving parts such as gears, belts etc. should be guarded to avoid accident to personnel. There
are chances for hand injuries or loss of limbs if the moving parts are not properly covered.

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(a) Swing Radius

Swing radius is the area through which the rotating structure of a crane rotates. All personnel in the
operating area are to stay out of the swing radius of the crane. It is important that barrier guards are
rigged before the operation to show the swing radius.

(b) Operation Near Electric Lines

All operations shall be performed in full Crane operation near electric
compliance with applicable legislation. Any lines
boomed equipment (e.g.: crane, backhoe, side
boom) operating within the boom length of the
minimum safe distance (as specified in the table
below) of any electrical line will have a
competent signalman.
When operating, no part of any crane or its load
will be permitted to approach near to any power
line than the distances specified below, unless
the electrical authority has been notified and the
line de-energized. The following is a guideline for
minimum approach separations when operating
in proximity to live conductors.

Minimum safe distance from live electric Closest Approach (meters/feet)
power lines Voltage (V)

750-150,000 3/10

150,000-250,000 4.5/14
6/19
over 250,000
(or legislated requirements where applicable)

Use extreme caution when working in proximity to radio transmission towers.

Caution will be exercised when working near overhead lines having long spans.

Cage type boom guards, insulating links, and proximity warning devices have limitations and the use
of them does not reduce the requirements above.

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It will be the responsibility of the person operating the equipment to ensure that work does not
proceed until the following-steps have been taken:

 Provision of qualified signalman.
 Steps taken to provide advance notification to the electrical authority.
 Fully informing the electrical authorities as to when the operations are to begin, complete and

when any location changes are planned and where.
 Whenever the specified equipment repeatedly travel beneath power lines, a route is plainly

marked and “rider poles" are erected on each side of the crossing.
 If the equipment is working in a relatively fixed location, it shall be electrically grounded.
 Ensure that warning signs are in place on all sides of the overhead power lines from which the

equipment approach is possible.
 Report every incident involving contact with a live line to the electrical authority and contractor

so that inspections and repairs can be made and prevent damaged live lines from failing and
broken down at a later date.
 Completely inspect the machine for possible damage caused by the electrical contact and not
use the machine until necessary repairs have been done.

Ground rods should be placed as close to the machine as possible, the ground lead should first be
connected to the rod and then to the machine and all personnel will be instructed to stay clear of both
the lead and rod at all times. When removing the ground, the lead should first be disconnected from
the machine. If a ground mat is used, the equipment will be placed on the mat and bonded to it. The
ground mat area should be enclosed with a fence to prevent personnel from stepping on and off the
mat during operation of the machine.
In the event the equipment or load makes contact with an energized circuit the operator will, if
possible:

 Remain inside the cab.
 Instruct all other personnel to keep away from the machine, rope and load.

Try, unaided, and without anyone approaching the machine, to back off the equipment until it is well
clear of the power line {if the machine cannot be self-propelled away or disentangled from the line,
remain inside the machine until the electrical authorities de-energize the circuit and confirm that
conditions are safe).

If the operator decides to leave the machine, he/she must jump clear. The operator must not, under
any circumstances, step down allowing part of his/her body to be in contact with the ground while
any other part is touching the machine. Because there may be a hazardous voltage differential on the
ground, the operator should jump with his/her feet together, maintain balance and shuffle slowly
across the affected area. The decision to stay within the crane cabin or leave it will depend entirely
on the circumstances surrounding the incident After contact with a power line the crane shall be taken
out of service and will be subjected to complete inspection, testing and certification by a third-party
agency prior to put on working again.

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c) Obstructed vision
Whenever the operator has his vision obstructed, a single competent signal man will be stationed:

 In full view of the operator.
 With a full view of the intended path of travel of the equipment, load or components, yet clear

of the intended path of travel.
He will assist the operator by keeping the obstructed part of the equipment under observation
and when it is out of view of the operator, by communicating with him by the use of visual
signals or a suitable communication system.
The signalman will:
 Be fully qualified and competent.
 Wear high visibility gloves or vest.
 Use hand signals only when conditions are such that his signals are clearly visible to the
operator (the signaler will review the signals prior to starting the operation), otherwise use
radio communication.

d) Guardrails

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Runways and steps need to have guardrails, handholds and slip resistant surfaces to avoid falling from

the crane.

b) Boom Angle Indicator

A boom angle indicator must be on the crane which shows the angle of the boom. Now a days the
boom angle indicator is a digital one which will be fitted on the operators’ panel.

b) Supporting Surface

Crane must be on a firm supporting surface to hold the weight equally on to all outriggers. If the
surface of any of the out rigger is not strong enough to support the outrigger, planks as shown in the
figure may be provided to overcome this problem.

OUTRIGGER SUPPORTING SURFACE

Travelling with a Load

Extreme caution will be exercised when moving a crane with load, and the following precautions will
be taken:

 The travelling procedures will be in accordance with the manufacturer’s recommendations.

 Ground irregularities will subject the carder, boom, and suspension to additional shock loads,

which will be compensated for by reducing the hook load, or by levelling the ground.

 Negotiation of slopes by cranes travelling with suspended loads will be avoided.

 The boom will generally be carded in line with the direction of motion.

 Where permitted by the design, the crane operator will remain in the crane cab to control the

load and a second operator will be used to drive the vehicle. The signalman (with the assistance

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of others, if required) will coordinate the operation, walk ahead of the load, and warn of
hazards.
 The load will be kept as close to the ground as possible such that the length of hoisting cable
between the boom point and load is as great as possible.
 The crane will be snubbed to prevent it from running away if the clutch or brakes fail on steep
slopes or in hazardous conditions.
 Care and awareness when approaching sub-grade structures (culverts, etc.) required to ensure
that the supporting capacity of any structure is not exceeded
Inspection of the hoisting machinery must be made by a competent person. The employer must
maintain a record of these inspections. The operating procédure as well as the physical status of the
crane can be inspected to keep the crane operations safe.
The sheaves must be smooth and free from surface defects otherwise it could cause rope damage.
Even the externally damaged rope also can damage the sheaves.

Damaged Sheaves

The defective ropes are to be immediately removed from use. The defective ropes may not have that
strength suggested by the manufacturer. Defects can be internal or external; the external damage of
ropes can be seen during visual inspection. Internal damage can be found by taking the diameter of
the rope using a Venire calipers.

Loose or defective parts should not be there on a crane. Conduct regular inspections of the crane for
defective parts or for the conditions of the tyres.

Tyres are to be fully inflated. In addition to the points explained above paragraph no. 3.11.4 may also
be referred for the inspection.

Defective Parts of a Crane

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In a crane set up the crane shall:
 Be inspected by a competent professional engineer (who is competent for the purpose of the
inspection) before use for the first time. The frequency of inspection is twelve months
thereafter.
 Be set up within 1 % of level grade and located on firm footing.
 Have all outriggers and pads in use as specified by the manufacturer.
 Have an anti-two block device fitted.
 Have positive locking latch fitted to the hook that is in good working order.
 Not to be loaded in excess of 25% of its maximum rated load capacity at the boom angle and
radius configuration. Hoisting and lowering speeds will be under power and will not exceed 30
meters per minute.
 Have a braking system that engages automatically in the event of an engine failure.
 Have a load monitoring device to verify the lift weights

Trial lifts with the empty basket will be made to the location where the basket will be positioned, and
repeated each time the crane is repositioned, and at the start of each shift.
The crane operator will remain with the crane at all times, with the engine running, while personnel
are suspended in the basket. No other loads may be combined with the basket.

A permit and lift calculation form is required each time the basket is used. Multiple lifts from the
same crane in the same position only requires one permit, although a new permit is required at the
start of each shift. A copy of the permit and ¡¡ft calculation will be kept by the crane operator.

The following will also apply:

 A competent worker will inspect the crane’s structural elements and the rigging for defects
before each use of the crane.

 Wherever required, notify the prevailing legislative authority before beginning any hoisting
operation.

 Every worker involved in the operation will receive adequate instructions about the
requirements, restrictions, hazards, and emergency rescue procedures associated with the
hoisting operation at a pre-lift meeting.

 Radio communication will be maintained between workers in the basket, the crane operator,
and the foreman. There will be at least two radios in the basket, and all radioswill have fully
charged battery units at the start of hoisting. Hand signals to be used in case of emergency
will be verified before hoisting commences.

 Workers shall keep all parts of their bodies within the basket when it is being raised and
lowered.

 Tag lines will be used for all lifts, except where their use constitutes a hazard.
 No hoisting will take place during high winds, lightning, or other adverse weather conditions.
 No hoisting will take place near energized electric wires if exceeding the recommended closest

approach guidelines found elsewhere in this HSEMS programme manual.
 All workers will wear a fall arrest system attached to the proper anchor points.
 The basket will be secured to the structure if workers will exit it at an elevated position.

MECHANICAL AND MANUAL HANDLING
Lifting operation generally requires training. Improper lifting operation is hazardous. Two types of
equipments are to be considered in connection with the lifting jobs one is the lifting equipment itself
and the other is the device which is used to connect the toad to the lifting equipment. This device is
known as lifting gear. Every lifting equipment / gear has the maximum load limit for lifting. There are
two terms used for representing this maximum load. One is WLL (Weight Load Limit) and the other is
SWL (Safe Working Load). The weight load limit is the maximum load the equipment can safely lift.
But it does not consider the service conditions. At a given service condition, the maximum load limit

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is to be estimated by a competent person. The maximum load limit assigned by the designer
/competent person after taking into account the service conditions of the machine is known as SWL
(Safe working Load) WLL is specified by the manufacture and SWL is specified by a competent person.
The value of SWL is less than WLL.
Manual handling refers to any activity which requires a person to use force to lift, lower, push, pull,
carry or otherwise move, hold or restrain objects. Almost a quarter of all injuries at work are caused
by accidents during manual handling. Most of the injuries are to hands, feet, legs and back. Some of
the back injuries results in permanent disability. Although the manual handling operations do not
specify what weight a person can lift, it is now recognized that one person should not lift any load
exceeding 20kg (44 lb). But in our country the safety provisions of the Factories Act suggest the
manual lifting load limit for different categories of employees

Mechanical Handling

When considering mechanical handling two equipment are used;

Lifting Equipment
Any mechanical device capable of raising or lowering a load is known as lifting equipment. Cranes,
Forklifts, Lifts, Suspended cradles, Powered hoists, Manual hoists, and Beam trolleys are examples
for lifting equipments.

Lifting Gear

Any device, whatsoever, which is used or designed to connect a load to lifting appliances which does
not form a part of the load is known as lifting gear. Wire rope slings, chain slings, hooks and fittings,
swivels, shackles, and eye bolts are some of the examples for the lifting gears. Among these the slings
which are used with the crane are important. All the lifting gears especially slings are to be inspected
before and after the use.

Web Sling

Web sling is made of nylon, polyester or polypropylene. Following are some of the advantages of a
web sling;

 The width and softness mean fewer tendencies to crush fragile

 objects, to mar or scratch finely machined, highly polished or

 The flexibility helps to mould them to the shape of the load.

 They are not affected by moisture and certain chemicals.

 They are non-sparking and can be used safely in explosive

 They minimize twisting and spinning during lifting. HLlHl

 Inspect visually before use.

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Chain Sling

Chain sling should not be subjected to the following
 Never use a chain in which the links are locked, stretched,
 or are without free movement.
 Never hammer a chain or hook into position.
 Never use an excessively pitted, corroded or worn sling.
 Do not carry a load on the point of the hook or insert the point into a chain link.
 Do not put hands or fingers between the sling and its load while the sling is being tightened
around the load.
 Do not allow loads to fall on to a sling.
 Do not cross, twist, kink or knot a sling.
 Do not drag a sling along the ground
 Do not use a sling over sharp corners without protective padding.
 Do not insert bolts or spikes to shorten slings.
 Avoid sudden jerks when lifting, take up the slack then apply the load slowly

Wire Sling

Following are some of the usual damages and problems of a wire sling;
 Mechanical damage.
 Wire fracture.
 Core break-up.
 Core protrusion.
 Wear and deformation at parts badly kinked.
 Broken outer and inner wires at ferrule.

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 Splits in ferrule.
 Neck breaks - broken strands and wires at neck shank.
 Kinking.

Wire Rope

Following are some of the standards the wire rope must have;
 The rope must possess sufficient strength to take maximum load.
 The rope must withstand repeated bending without failure of the wires from fatigue.
 The rope must resist abrasion and corrosion.
 The rope must withstand distortion and crushing.
 The rope must resist rotation.

Safe Sling Angle

As the sling angle increases, (the length of the sling is short) the load on each leg also increases. This
should be kept in mind during lifting operations.

Safe Working of Cranes

For the safe working of a crane the following are important;
Disposition of damaged rope is as follows;

 Six wires broken in one wire lay.
 Three wires broken in one strand on one rope lay.
 Wear of one-third of the original diameter of the outside individual wires.
 Rope severely kinked, crushed, cut, unstrained, or any other damage resulting in distortion of

rope structure.
 Considerable corrosion in the valleys between strands.
 Reduction from nominal rope diameter.

(a) Unsafe working and accidents are the results of;

 Lack of training or knowledge.
 Poor maintenance.
 Proper plant or equipment not being available.
 Misuse of plant or equipment.
 Undue hurry to get the job done.

(b) Safe systems of work can be achieved by;

 Proper planning and use of suitable cranes.

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 Maintenance and testing of equipment.
 Supervision of work.
 Test certificates and documents.
 Prevention of unauthorized use.
 Safety of all persons.

(c) For the safe operation of a crane the toads must be;

 Correctly slung.
 Made secure.
 Clear of obstacles.
 Palletized loads netted.
 Loose materials lifted in a container.
 Have a tag line attached.
 Clear of people and equipment.

(d) Primary basics of rigging

 Determine the weight of the load.
 Determine the centre of gravity of the load
 Determine the type of slings and rigging equipment best suited for the type of load.
 Properly inspect all rigging equipment prior to application,
 Apply a hitch that will hold and control the load.
 Protect the rigging equipment from sharp, unyielding surface.
 Protect the load, if necessary, from being damaged by the rigging equipment.
 Check out the hoisting devices to assure that its limitations will not be exceeded.
 Know load movements and locations prior to lifting the load.
 Maintain load control from start of the lift to completion.
 Keep all personnel clear of suspended loads.
 Use proper hand signals during load movements.

(e) Twelve steps that may lead to an accident

 Operating the equipment without proper training and authorization.
 No securing equipment or work space against unexpected movement, as in shoring up a

trench.
 Operating the equipment at over the allowed speed, without regard to recommendations.
 Not signaling or warning your co-workers of heavy equipment movement or other potentially

dangerous situations.
 Disconnecting hazard lights and audible warning devices.
 Using tools and equipment in spite of they are not working properly.
 Ignoring safety assessment procedures, especially checklist.
 Avoiding or delaying calibration, repair, adjustment, or any scheduled services on your tools

and equipment.
 Hitching a ride on heavy moving equipment.
 Ignoring body position recommendations appropriate for the task.
 Initiating horseplay on the job site.
 Not wearing PPE

Use and Inspection of Rigging

This procedure applies to all rigging equipment, including wire rope and slings, chains, synthetic
(polyester/nylon) slings, lever hoists, chain falls, shackles, hooks, lifting / spreader bars, clamps, and

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any other load bearing hoisting attachment. The safety factor will be / increased if there is any
possibility of injury or death due to failure of the rigging.
The working loads of rigging will not exceed the safe limits established by the manufacturer. Any
rigging that has been fabricated will be designed and certified by a professional engineer, and will
have the safe working load clearly stamped on it.
All rigging equipment will be permanently identified with the safe working load apd unique serial
number.

Inspection
Rigging equipment shall be inspected by experienced personnel in rigging at least once in a month,
but more frequently (weekly or even dally) if used continuously. Damaged rigging equipment will be
removed from service and scrapped.
An inspection log will be maintained for all rigging equipment. Manufacturer’s recommendations
regarding criteria that necessitate repair or replacement will be followed,

(a) Slings and Wire Ropes

Sharp edges of loads will be protected with wood softeners or other soft material to protect the slings.
Wire ropes and Slings shall be inspected for corrosion, kinks, abrasion, electric arcing, metal fatigue,
bird caging, diameter reduction and broken strands.
Synthetic slings shall be inspected for evidence of exposure to heat, cuts or frays, or if there are
indications of wear (internal or external).

(b) Chains

Avoid the use of chains when it is possible to use wire rope. Chains usually give no warning when they
are about to fail, whereas wire ropes will normally fail progressively, and frequent inspections can
detect damages. Chains shall be inspected for wear, deformation, cracks, or stretch (against a new
chain with master link kept for the purpose). The chain shall not be wrapped around the load for
hoisting. Chain falls will not be overloaded. The average pull required on a standard come-along
handle or chain fall chain varies between 20 and 45 kilograms, and the application of excessive
leverage or weight will overload the equipment. Even the body weight of one person hanging from
the lever or chain is a sign of overloading. Only one person will pull the chain or operate the lever at
a time.

(c) Hooks and Shackles

All hooks will be made from forged steel with the safety rating stamped on it, and will have working
safety catches. Shackles will not be used in such a manner that the rope can run over the screw pin.
The screw pin will seat fully into the body, and bolts will not be used to replace missing pins.

(d) High Lines

The use of high lines is not permitted. A high line is a method used to position a piece of equipment
that is not accessible by crane (usually inside a building or structural enclosure). It consists of lashing
wrapped around two building members and a wire rope pulled tight between them - a snatch block
on the lashing is then used to lift the load and move it laterally.

(e) Crane Suspended Worker’s Basket

Personnel baskets will only be used when conventional methods of access cannot be used due to the
site configuration or conditions, or specific hazards. All crane-suspended personnel baskets shall be
used and maintained in full compliance with applicable legislation.

The basket will meet the following requirements:
 Be designed by a professional engineer in accordance with good engineering practice. A signed,
stamped drawing will be provided showing empty weight, maximum rated load capacity,
maximum number of people, and serial number.

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 Be of welded construction by a certified welder, with a design safety factor of 10.
 All rigging components shall have a minimum safety of 10.
 Be of a box design having the lifting points in the top four corners, and enabling the workers

to stand upright with sufficient headroom.
 Have a bridle sling arrangement that evenly distributes the weight between each sling, and

will prevent tipping. The bridle sling and other rigging attachments shall be a permanent part
of the basket and will not be used for any other purposes.
 Have a handrail 1070 millimeters from the floor and a mid-rail halfway between the handrail
and floor
 Have a toe board 100 millimeters high
 Have solid material or expanded metal (with 13-millimeter maximum openings) below the
handrails.
 Have an inward opening gate with a positive closing latch.
 Have a solid non-slip floor with stiffeners on the underside and some appropriate method of
allowing water run-off.

Manual Handling

Moving or supporting a load by hand or bodily force is known as manual handling. Injuries due to
manual handling may be classified under two main headings - External injuries and internal injuries.
Examples of external injuries are cuts, bruises, crush injuries, lacerations. Generally, these types of
injuries are not as serious as internal injuries.
Internal injuries are muscle and ligament tears, ruptures, slipped discs, knee, ankle and shoulder
injuries. One of the most serious injuries is the slipped disc which results in frequent incapacity and
may even be permanently damaging.
The spine or backbone is the principal supporting structure in the body which provides strength and
stability to the body. It has three main functions;

 It is the scaffolding of the body supporting the skull and anchoring the ribs, pelvis and shoulder
bones.

 It provides points of attachment for the muscles, tendons and ligaments that enable the body
to move.

 it contains the spinal cord, which carries messages to the brain from all parts of the body.
 Have anchor points for worker’s fall arrest systems above the headache ball or other

attachment.
 Have a grab rail inside the handrail to minimize hand exposure.
 Have the empty weight, maximum rated load capacity, maximum number of people, and a

unique serial number legibly and permanently marked in a conspicuous place on it.
 Be painted in a high visibility yellow colour.
 Have a safety wire rope sling be attached to the basket at a separate location from the primary

point of suspension. The other end of the safety line will be attached above the ball or above
the hook on the block.
 Be certified every twelve months.
 Not be used as a materials hoist.

If shackles are used as part of the arrangement, ensure that they are cotter pinned or moused to
prevent ‘'turn-out’’.
When people are lifting, pushing, pulling or simply leaning forward over a work surface they tend to
keep their legs straight and incline the trunk forwards. This is potentially a harmful position. As we
lean forward part of the motion occurs at the hips, but the rest occurs by bending of the spine, by
first flattening and then reversal of the lower back curve. For this to occur, the disc must be deformed
in to a wedge shape. Lifting weights in this position is hazardous.

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An ergonomic approach towards good technique for lifting and moving of load will reduce the risk
from manual handling operations. Information and training on safe manual handling should be
provided to all handlers,

Common Causes of Back Injuries
 Heavy lifting, especially repetitive lifting over a long period of time
 Twisting at the waist while lifting or holding a heavy load.
 Reaching and lifting over your head,
 Lifting or carrying objects with awkward or odd postures Working in awkward, uncomfortable
positions.
 Sitting or standing for a long time in one position.
 It is also possible to injure your back slipping on a wet floor.

Good Handling Techniques for Lifting
Take care of yourself by following the guidelines given below:
If mechanical handling equipment is available and you are authorized and trained to use it, do so.
Wear the right protective equipment for the job.
Know your physical capabilities and only undertake jobs you can reasonably handle.
Think the job through:

a) Can you handle the load by yourself?

b) Is there a clear, properly lit, walkway to the work or stacking area?

c) Is there a safe stacking area?

d) Will timber packing be required between the articles when stacked?

e) Seek advice on height restrictions for stacks. Remember, it is often more dangerous de-
stacking than stacking.

f) Always check the weight of the load before lifting.

Know the correct way of lifting before attempting a lift:

a) Stand reasonably close to the load, be sure footing is firm and feet are about 300 mm apart.

b) Squat down by bending the knees, keeping the back as straight as you can.

c) Place hands where they will not slip, and grip firmly.

d) Breathe in before lifting - inflating the lungs helps support the spine.

e) Straighten up with the legs, keeping the back as straight as you can

f) Hold the load firmly and close to the body.

g) Ensure your view is not impeded by the load whilst working with it.

h) Lift slowly and smoothly. Avoid jerking motions.

When two or more persons lift a load, one of the team must be nominated to give instruction to ensure
that each person lifts an equal share and the team work

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Member MSME & National Safety council (NSC) 77

A ISO 9001: 2015 Organization

Construction Safety

www.skillmartacademy.com; contact :[email protected];

[email protected],

SMI: mLearn (App). Reach us @ 90044 55666; 90049 82333

Member MSME & National Safety council (NSC) 78

A ISO 9001: 2015 Organization

Construction Safety

www.skillmartacademy.com; contact :[email protected];

[email protected],

SMI: mLearn (App). Reach us @ 90044 55666; 90049 82333

Member MSME & National Safety council (NSC) 79