A Case Study on OHS Practices in Steel Re-rolling Mill, Islamabad

An Evaluation of OHS Practicesin Steel Re-rolling Mill, IslamabadHIRA AMJAD, ZAHIRUDDIN KHAN, SAJEELA GHAFFARPhD Candidate Environmental EngineeringIESE-SCEE, NUST

Sequence of presentation• Introduction• Objectives• Methodology• OHS hazards in Steel Mills• Results & Discussion• Conclusions• Recommendations• Acknowledgment• References2

Introduction• Occupational health and safety is a crossdisciplinary area concerned with protecting thesafety, health and welfare of people engaged inwork or employment.• Due to the globalization of trade, severalorganizations are now involved in:◦ monitoring unfair labor practices◦ environmental health and◦ safety conditions in developing countries• Pakistan has joined the World TradeOrganization (WTO).3

Introduction• According to the WTO requirements, foreigninvestors require compliance of the localindustry with international standards i.e. ISO• In 2001, the government announced a LaborPolicy Initiative and proposed to create aNational Occupational Safety and HealthCouncil (NOSHC)• Due to this negligence, the local industry couldcost the country billions in international trade.4

Objectives5

• To look at the OHS practices in Pakistan’ssteel re-rolling mill• To compare the local steel re-rollingindustry processes with internationalindustry processes• To raise the OHS awareness in the caseindustry studied6

Methodology7

• Desk study to collect the necessaryinformation• Checklist designed• Visit to steel re-rolling unit to observeOHS issues• Comparison of local and internationalsteel industry processes8

Potential OHS hazards in Steel Mills• Explosion and burn hazards (spills ofmolten material, piping network of fuelgases and oxygen)• Chemical Hazards (MSDS, acids, ammonia,asbestos and CO)• Dusts (iron oxide, coal, coke and silica)• Heat is largely generated and used in asteel plant• Noise is also a physical hazard in a steelmill10

Results & Discussion11

OHS practices in International SteelMills• The original code of practice on safetyand health in the iron and steel industrywas adopted at a meeting of experts in1981.• Governing Body of the ILO at its 28thSession in November 2003, drew up andadopt a revised code of practice on safetyand health in the iron and steel industry.12

<strong>Case</strong> study of Corus EngineeringSteels, UKCES• Two computercontrolled bloom reheatingfurnaces• In line sawing• Controlled coolingfacilities• In line automaticproduct stampingand samplingLocal industry• Two manuallycontrolled re-heatingfurnaces• Manual sawing bycrews• Uncontrolled coolingfacilities• Manual productstamping13

OHS practices in PakistanSteel Mills14

<strong>Case</strong> study of Ittehad SteelMill• In 1978, they had started a steel manufacturingfacility in Islamabad• The Ittehad Group is a privately-held, diversifiedPakistani Conglomerate with interests in: steel,real-estate, logistics, automobiles, hospitality andgeneral trading• Largest Pakistani exporters of re-bars toAfghanistan and employing over 450 people• Group Turnover in 2007-2008 of over PkRs. 2billion15

Occupational Health andSafety issues in Ittehad RerollingSteel Mill• Relatively well-managed unit• Contractors are responsible forproduction & dealing with workers• A number of OHS issues are figured outin the unit during the OHS audit16

Manual handling of heavy load• Workers have touplift steel blocksof 60-90 Kg weight17

No MSDS displayed• No MSDS to guide the workers about thehealth and safety issues at the work place.18

Fire extinguishers• Do present in store room but are notdisplayed on proper points even in theoffice areas.19

Emergency exits• No emergency exits are marked• No emergency training or drill• No emergency procedures• No warning alarm exists in case of fire20

No Personal Protective Equipment• Workers are workingwithout PPE eventongs men areworking without PPE21

Regular training & drill• Only for some selected workers• Three days training about health andenvironmental issues22

First Aid• First aid facilities are present• A medical officer is present23

Machines are without guards andsafety devices• Automaticmachines and steelrollers are withoutsafety guards• No heat insulatingguard is placednear the hot areasof process24

Crowded walk ways• Walkways are verycrowded and full ofhurdles• Greasy and oilyliquids are presenton floor of walkways25

Indigenous cooling fans• Fans are used for cooling• Fans are without safety guards26

Electrical & Fire hazards• Electric boards areunattended andwithout any cover• Use of power boardsand extension chordsis pretty much high27

Poor house keeping• No health &hygiene measures• Walkways are notfree to move28

Excessive Noise• Noise level is very high atworkplace• No noise insulating systemis present29

Heat• In steel re-rolling mills heat isgenerated and used on highlevels• No insulating material ispresent around the furnace30

Conclusions31

• ISM need to develop “Safe WorkProtocol”• Contractors should make safetyprotocols mandatory32

Recommendations33

• OHS orientation training to all newemployees• Safe work practices, and emergencyprocedures for fire• Floors should be level, even, and non-skid• Clear passages to emergency exits34

• Measures to prevent unauthorized accessto dangerous areas• Provide sufficient fresh air to workers athot work spaces• In each shift rescuers should be definedand trained• Locking out and tagging-out practicesduring service or maintenance35

• Prohibit manual handling of heavyobjects that are more than 15 Kg• Energy efficient light sources shouldbe used that produce less heat• Active use of PPE should be mademandatory and force the workers towear the PPE36

Acknowledgment• Management Team of ISM particularly Mr.Muhammad Maruf, Sales Manager, IttehadSteel Mills, for his valuable informationsharing about the manufacturing processand OHS issues in the re-rolling unit.• IESE, NUST for all administrative support.• IEP for providing this opportunity.37

References• Fernández-Muñiz, B., Montes-Peón, J. M. and Vázquez-Ordás,C. J. (2009). Relation between occupational safetymanagement and firm performance. Safety Science. 47:980-991.• Moreau, D., T., R. and Neis, B. (2009). Occupational health andsafety hazards in Atlantic Canadian aquaculture: Laying thegroundwork for prevention. Marine Policy. (33): 401–411.• Rikhardsson, P.M., Impgaard, M. (2004). Corporate cost ofoccupational accidents: an activity-based analysis. AccidentAnalysis and Prevention. 36:173–182.• Worksafe Saskatchewan. Hamilton: CCOHS; c2008[citedJune14, 2008]. Ontario Workplace Safety and InsuranceBoard: Types of OHS hazards. [about 4 screens].Availablefrom: /http://www.worksafesask.ca/files/ont-wsib/ certmanual/ch-01.html#HealthandSafetyHazards>.38

References• World Trade Organization (WTO), Geneva, Switzerland.• Environmental, Health and Safety (EHS) Guidelines.General EHS Guidelines: Occupational Health andSafety. International Finance Corporation, World BankGroup.• Akram, M. (2004). Status Report on AIHA Participationfor the Improvement of Occupational Health, Safety andEnvironment in Pakistan for 2003 – 2004.• Safety and health in the iron and steel industry, Secondedition. International Labour Office, Geneva.• Workplace Health and Safety Handbook. (2006).Government of South Australia. Page no. 113-116.• www.corusgroup.com39

Questions &Answer40