TUTORIAL : MODULE 3

CLASSROOM ACTIVITY ON SAFETY IN

CONSTRUCTION INDUSTRY

Overview of Safety in Construction

Safety in construction is paramount due to the high-risk nature of the work

involved in building, testing, and commissioning industrial plants and
equipment. Safety concerns during the construction phase differ significantly
from those during regular operation and maintenance. Construction projects
involve multiple stages, including civil works, material storage, erection,
testing, commissioning, and trial operations, each with unique hazards and
safety challenges.

Stages of Construction and Associated Safety Concerns

1. Civil Works:
o Hazards: Pitfalls, falling objects, and structural collapses.
o Safety Measures: Proper site management, securing trenches, and
using protective barriers to prevent accidents.

2. Receiving and Storage of Materials and Equipment:

o Hazards: Fire hazards, mishandling of materials, and improper
storage.
o Safety Measures: Organized storage, regular inspections, and
ensuring that materials are stored in secure and appropriate
locations.

3. Erection:
o Hazards: Falling from heights, crane failures, falling equipment,
and fires during welding.
o Safety Measures: Use of fall protection systems, regular
maintenance of lifting equipment, and fire safety protocols during
welding.

4. Testing and Commissioning:

o Hazards: Electrical shocks, fires, explosions.
 o Safety Measures: Ensuring proper insulation, using protective
gear, and adhering to electrical safety standards.

5. First Energizing and Trial Operations:

o Hazards: Unexpected equipment failure, electrical hazards.
o Safety Measures: Comprehensive pre-energization checks, use of
protective equipment, and strict adherence to safety protocols.

6. Handing Over to Operating Staff:

o Hazards: Lack of familiarity with equipment leading to
operational errors.
o Safety Measures: Proper training and thorough documentation
during the handover process.

Common Construction Hazards

 Falling Persons: Due to inadequate fall protection.

 Falling Materials: Poorly secured loads or equipment.
 Transport Machinery Accidents: Unsafe operation of vehicles and
machinery.
 Lifting Equipment Failures: Malfunctions or improper use of cranes
and slings.
 Excavation Accidents: Cave-ins and falls into excavated areas.
 Fires and Explosions: During storage, welding, or due to electrical
faults.
 Structural Collapses: Due to improper shoring or underpinning.
 Electrical Accidents: Shocks and burns from live wires.
 Lightning and Natural Disasters: Inadequate protection from natural
elements.

Excavation and Filling

 Hazards:
o Cave-Ins: Due to unstable soil.
o Falls and Falling Objects: Into or within the excavation site.
o Underground Utilities Damage: Causing fires, explosions, or
toxic gas leaks.

 Safety Measures:
 o Verification of Underground Installations: Isolating or
protecting existing utilities.
o Fencing and Barricading: To prevent unauthorized access and
falls.
o Proper Lighting: Especially during night work to prevent
accidents.
o Use of Ladders: For safe access in trenches deeper than 1.5
meters.
o Vibration Control: To prevent soil failure from nearby traffic or
machinery.

Under-Water Works

 Hazards:
o Compression and Decompression: Risks like the bends due to
rapid ascent.
o Nitrogen Narcosis: Affects similar to alcohol intoxication from
increased nitrogen absorption.
o Oxygen Toxicity: Due to higher oxygen levels causing
disorientation, seizures, or death.

 Safety Measures:
o Proper Training: Workers must be well-versed in the physics and
chemistry of underwater work.
o Equipment Checks: Regular inspections of diving gear.
o Rescue Plans: Always have a decompression chamber and rescue
team ready.
o Controlled Ascent and Descent: To prevent decompression
sickness.
o Work Planning: Ensuring workers understand the impact of
underwater conditions on construction activities.

Under-Pinning

 Hazards:
o Collapse of Structures: Due to improper excavation or lack of
support.
o Confined Space Risks: Limited escape routes and exposure to
harmful gases.
 o Structural Failures: Resulting from inadequate strengthening of
superstructures.

 Safety Measures:
o Pre-Excavation Investigations: To check for services and
structural integrity.
o Support and Shoring: Adequate support for excavations and
nearby structures.
o Ventilation and Access: Ensuring safe entry and exit points in
confined spaces.
o Use of PPE: Proper protective gear for all workers.

Shoring

 Hazards:
o Collapse During Installation or Use: Due to improper setup or
defects in equipment.
o Falls: From improper use of shoring systems.

 Safety Measures:
o Pre-Installation Surveys: To identify potential hazards.
o Qualified Supervision: Ensuring only qualified personnel manage
the shoring system.
o Regular Inspections: Continuous monitoring of the shoring
system throughout the project.
o Proper Use and Handling: Ensuring that shoring equipment is
used as intended and not for unauthorized purposes.

Indian Standards and National Building Code Provisions:

1. IS 3764:1992 - Excavation work - Code of Safety.
2. IS 11972:1987 - Safety requirements for underwater diving operations.
3. IS 12353:1988 - Safety code for shoring and underpinning operations.
4. IS 3696 Part 1 & 2 - Scaffolds and Ladders - Safety Code.
5. IS 4756:1978 - Safety code for tunneling work.
6. IS 4081:1986 - Safety code for blasting and related drilling operations.
7. IS 4130:1991 - Safety code for demolition of buildings.
8. IS 14489:1998 - Code of practice on occupational safety and health audit.
 9. IS 875 (Part 4):1987 - Code of practice for design loads (other than
earthquake) for buildings and structures.

Read the Story: Building Tomorrow's Safe Havens

Once upon a time in the bustling city of Greendale, a new project was about to
take shape—a state-of-the-art, eco-friendly residential complex named "Green
Horizons." This project was unlike
any other in the city, not only
because of its commitment to
sustainability but also because of its
strict adherence to safety protocols.
The city had witnessed several
construction-related accidents in the
past, and the developers of Green
Horizons were determined to set a
new standard for safety in the
construction industry.

The project was spearheaded by

"EcoBuild Constructions," a
renowned construction company known for its innovative and safe construction
practices. EcoBuild had been entrusted with the task of transforming a barren
plot of land into a lush, green residential paradise. The project involved various
complex construction operations, each with its own set of challenges and safety
concerns.

The first phase of the project was Excavation and Filling. The land where
Green Horizons was to be built had uneven terrain, requiring extensive
excavation to lay the foundation. The workers had to dig deep trenches to
stabilize the ground. However, the company knew the risks involved—trenches
could easily collapse, leading to potential fatalities. To prevent such disasters,
EcoBuild implemented shoring techniques, installed trench boxes, and ensured
that only authorized personnel could access the excavation site. The project
manager, Mr. Rohan, held daily safety briefings to remind everyone of the
dangers and the importance of vigilance.
The second phase involved Under-water Works. The complex included an
artificial lake, and to construct the foundation for a bridge that would span
across it, the workers had to perform underwater construction. This was perhaps
the most perilous part of the project. Specially trained divers were brought in,
equipped with state-of-the-art diving gear. The site was monitored 24/7 to
ensure that the water pressure remained stable and that all equipment was
functioning correctly. The divers faced numerous challenges, from strong
currents to the potential malfunction of their gear. But thanks to the rigorous
safety protocols and constant communication, they successfully completed the
underwater tasks without incident.

The final major operation was Under-pinning & Shoring. Adjacent to the
Green Horizons site stood an old building that had to be reinforced before any
further excavation could be done. The project required carefully placing
temporary supports to prevent the building from collapsing while work
continued underneath. This was a delicate operation that required precision and
constant monitoring. The workers used advanced shoring materials and
techniques to ensure the stability of the old structure. Weekly inspections were
conducted by both the project engineers and external safety auditors to ensure
that everything was in order.

Despite the complex nature of these operations, EcoBuild's commitment to

safety ensured that not a single worker was injured throughout the project. The
story of Green Horizons quickly spread across the city, becoming a beacon of
how construction could be both innovative and safe.

Inspired by this success, the city of Greendale decided to make safety training a
mandatory part of all future construction projects. They adopted new standards,
modeled after the practices used in Green Horizons, ensuring that the city's
future growth would be both sustainable and secure.

Revised and Engaging Activity: Green Horizons Construction Challenge

Part 1: Green Horizons Construction Simulation

Scenario: You are now part of the team at EcoBuild Constructions, responsible
for building the "Green Horizons" residential complex. This project includes
critical operations like Excavation and Filling, Under-water Works, and Under-
pinning & Shoring. Your goal is to ensure that these operations are carried out
safely while meeting the project's sustainability goals.

Instructions:

1. Group Formation:
o Divide the class into teams of 4-5 students. Each team represents a
different department within EcoBuild Constructions.
o Assign each team a specific construction operation (e.g., Team A
handles Excavation and Filling, Team B handles Under-water
Works, Team C handles Under-pinning & Shoring).
2. Creative Simulation:
o Using materials such as Lego bricks, cardboard, paper, and other
craft supplies, each team will simulate their assigned construction
operation.
o Teams must plan their construction operation, considering the
safety issues that EcoBuild encountered during the Green Horizons
project.
o Each team will design a safe and efficient plan for their operation,
incorporating the innovative safety measures used by EcoBuild.
3. Safety Considerations:
o Excavation and Filling: Preventing trench collapses, using
shoring techniques, managing site access.
o Under-water Works: Ensuring diver safety, managing water
pressure, preventing equipment malfunctions.
o Under-pinning & Shoring: Preventing structural collapse, proper
placement of shoring materials, continuous monitoring.
4. Role-Playing:
o Each team will role-play as the project managers and workers.
They will simulate a day in the life of the construction site,
highlighting the safety protocols they are following.
o Use storytelling, creative presentations, and even mini-dramas to
bring the scenario to life.

Presentation:
  After completing the simulation, each team will present their construction
plan and role-play scenario to the class.
 They must explain the safety measures they implemented, justify their
choices, and reflect on how they ensured the project’s success.
 Encourage creativity in their presentations—teams can use digital tools,
create videos, or even act out potential hazards and their solutions.

Part 2: Safety Standards Familiarization - "Becoming Safety Experts"

Scenario: EcoBuild Constructions set a new standard in safety with the Green
Horizons project. Now, it’s your turn to become safety experts by learning
about the Indian Standards and National Building Code provisions that guided
their operations.

Instructions:

1. Research and Role Assignment:

o Each team is assigned a specific standard related to their
construction operation (e.g., IS 3764:1992 for Excavation, IS
11972:1987 for Under-water Works, IS 12353:1988 for Under-
pinning & Shoring).
o Teams will research their assigned standard, understand its
importance, and relate it to the work they simulated in Part 1.
2. Creative Summary Creation:
o Teams will create a one-page summary of the standard, but here’s
the twist: they must present the information in a creative format.
This could be a comic strip, a safety manual, an infographic, or
even a short video.
o The summary should explain the relevance of the standard to their
construction operation and highlight key safety requirements.
3. Peer Teaching:
o Each team will present their creative summary to the class,
effectively teaching their peers about the safety standard.
o The class will engage in a discussion about how these standards
ensure safety in real-world construction projects, using the Green
Horizons project as a reference point.
Reflection:

 At the end of the activity, students will reflect on what they learned about
construction safety and how these lessons can be applied in real life.
 Discuss how safety standards evolve and the role of engineers, project
managers, and workers in maintaining high safety standards.