Safety & Health in the Stone Crushing Industry - Occupational ...

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2 Acknowledgements M. Nithiyananthan and N. Wagner provided almost all photos in this manual including the title page photo. Perry Gottesfeld of Occupational Knowledge International provided the photo in the chapter "Reducing dust where water is available"; Development Alternatives provided the photo in the chapter "Reducing dust where water is not available". M. Nithiyananthan created the illustrations in chapter B "Improving Heavy Physical Work". All other black & white illustrations in this manual are provided by the HESPERIAN Foundation and are reprinted with their permission. You can contact the HESPERIAN Foundation at: HESPERIAN Foundation 1919 Addison Street, Suite 304 Berkeley, CA 94704 USA Tel: (510) 845-1447, Fax: (510) 845-9141 Toll free in the US: (888) 729-1796 Email: hesperian@hesperian.org
3 Table of Contents Table of Contents .......................................................................................................................... 3 Foreword ........................................................................................................................................ 5 Eulogy............................................................................................................................................. 7 Introduction.................................................................................................................................... 8 A Safety & Health in Stone Crushing ...................................................................................... 9 A.1 A Word for the Owners: Managing Health and Safety in Stone Crushing.................... 10 A.2 Preventing Accidents in a Stone Crushing Unit............................................................ 14 A.2.1 Preventing Falls from Heights.................................................................................. 14 A.2.2 Working Safely with Electricity................................................................................. 16 A.2.3 Machines and Power Tools ..................................................................................... 19 A.2.4 Using Gas Cylinders Safely ..................................................................................... 21 A.2.5 Keeping the Roads Safe.......................................................................................... 22 A.2.6 Securing Access to the Plant................................................................................... 24 A.3 Keeping Workers Healthy............................................................................................. 25 A.3.1 Reducing Dust When Water is Available................................................................. 26 A.3.2 Reducing Dust When Water is Not Available .......................................................... 28 A.3.3 Protecting Hearing from Noise................................................................................. 32 A.3.4 Using Personal Protective Equipment (PPE) .......................................................... 34 A.3.5 Working Safely at Night ........................................................................................... 36 A.3.6 Fighting off the Heat................................................................................................. 37 A.3.7 Taking care of Human Needs .................................................................................. 39 A.4 Being Prepared for Emergencies ................................................................................. 40 B Improving Heavy Physical Work........................................................................................ 43 B.1 Main crusher operator .................................................................................................. 45 B.2 Repair and Maintenance of the Main Crusher.............................................................. 46 B.3 Aligning the portable bucket conveyor for loading........................................................ 47 B.4 Removing spilled stones.............................................................................................. 48 B.5 Leveling the Boulder Collection Pit............................................................................... 49 B.6 Cleaning work under the main crusher......................................................................... 50 B.7 Tally clerk work station ................................................................................................. 52 B.8 Maintenance work activities.......................................................................................... 53 B.9 Cleaning and housekeeping work around crushers ..................................................... 55 B.10 Going to the top boulder loading .................................................................................. 58
Page 3: SAFETY & HEALTH IN THE STONE CRUSHI
Page 7 and 8: 5 Foreword This manual is based on
Page 9 and 10: 7 Eulogy Mr. M. Nithiyananthan, the
Page 11 and 12: 9 A Safety & Health in Stone Crushi
Page 13 and 14: 11 how the work is done and how the
Page 15 and 16: 13 When writing down your results,
Page 17 and 18: 15 Picture 3: worker at the primary
Page 19 and 20: 17 Picture 5: electrical room used
Page 21 and 22: 19 − − − The transformers are
Page 23 and 24: 21 A.2.4 Using Gas Cylinders Safely
Page 25 and 26: 23 − − The conditions of trucks
Page 27 and 28: 25 A.3 Keeping Workers Healthy Ston
Page 29 and 30: 27 Flow Rate: The rate at which wat
Page 31 and 32: 29 Picture 11: dust capture with dr
Page 33 and 34: 31 Dust source with incomplete enca
Page 35 and 36: 33 Noise is mostly produced by eith
Page 37 and 38: 35 PPE might be needed throughout t
Page 39 and 40: 37 Metal sheets and other glare-ge
Page 41 and 42: 39 A.3.7 Taking care of Human Needs
Page 43 and 44: 41 Keep a system for head-count at
Page 45 and 46: 43 B Improving Heavy Physical Work
Page 47 and 48: 45 B.1 Main crusher operator Nature
Page 49 and 50: 47 Solutions: Proper platform shou
Page 51 and 52: 49 Solutions: Issue and use proper
Page 53 and 54: 51 − − Tripping and falling int
Page 55 and 56:
53 Picture 24: stone shed for worke
Page 57 and 58:
55 Picture 26: repairing the crushe
Page 59 and 60:
57 Proposed alternate for sieving o
Page 61 and 62:
59 B.11 Removal of Jammed Boulders
Page 63 and 64:
61 C How Much Does an Accident Cost
Page 65 and 66:
63 D Checklists and Benchmarks The
Page 67 and 68:
65 Area Yes No Comments / Action 3.
Page 69 and 70:
67 D.2 Checklist: Electrical Equipm
Page 71 and 72:
69 D.3 Checklist: Ergonomic Workpla
Page 73 and 74:
71 D.4 Checklist: Fire and Explosio
Page 75 and 76:
73 D.5 Checklist: Accident preventi
Page 77 and 78:
75 D.6 Checklist: Dust and noise re
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