Techniques for Safe Execution

Tata BlueScope Building Solutions successfully completed the safe execution of GE India´s manufacturing facility, with the adoption of innovative construction techniques. GE India Industrial wanted to set up a manufacturing facility at Chakan, Pune, to manufacture a host of different products. GE was looking for an engineered steel building solution that would create a safe working environment while meeting all their operational requirements. The company identified Tata BlueScope Building Solutions as having strong safety credentials that were in line with GE´s objective of completing the project safely. A case study has been conducted on this innovative safety approach which impressed GE India. The challenge The height of building is 24 m and working at height was identified as the critical risk. Planning for safe execution of the project Three months before the actual start of site activities, the team identified critical safety requirements of the project and prepared a ´safe work method statement´ for each activity, as well as a construction EHS plan. The team started pre-order discussions with the certified builder and got acceptance to follow ´all safety requirements without any deviations´. Keeping in mind the magnitude of the project, they introduced new policies such as ´No Supervision - No Work´, ´No Night Work´. The team conducted risk assessment for all the activities and suggested innovative solutions to reduce the risks involved. Occupational health and safety hazard register and a mitigation action plan was also prepared. An EHS induction area for visitors, equipment parking area, safety park, emergency response plan, emergency contact numbers, arrangements of first aid and ambulance with paramedical staff were well-thought of. During the project concept stage, some changes were suggested in the standard product design from the perspective of safe erection. Inspection to ensure quality of resources deployed on site: Tata BlueScope Building Solutions conducted a pre-entry inspection and green tag certification of all the equipment. Daily inspection check-lists were displayed on each equipment. Third party inspection of the equipment on site was also conducted. Due to safety reasons, use of hydra for material loading and unloading was not allowed. A detailed site layout plan for safe storage of materials and equipment movement in the yard was prepared. Display of visuals for safety management: To highlight the importance of safety to workmen, displays of safety cross, safety statistics, safety gallery were placed on site. Monthly EHS trainings: EHS trainings for staff, working at height training, safe lifting practices and fire fighting techniques for workmen, EHS recognition programs, EHS promotional activities, motivation programs were conducted. Safe Erection Methodology To achieve the objective of safe project completion, the following approaches were adopted on site: a. Reduce risk of working at height: To ensure complete safety while working at height, three levels of protection were introduced: (i)Working in boom lift for all work at height. (ii)Mandatory use of full body harness with double lanyard. (iii)SKY-WEB® II fall protection system was suggested to ensure safety during roof liner panel installation. Sitting on erected rafters, purlins, girts was not allowed. To restrict unauthorised entry, the work area was barricaded, and to prevent fall of tools from height, all tools were tied while working at height. The roof access staircase of British scaffolding type for roof access and an access control system was implemented during roof installation. Edge protection was also provided at the roof edge. The erection of components such as brace rods, girts, flange braces, pipe struts, sag angles, SKY-WEB® II, crane platform, flashings, were fixed using boom lifts and cranes. EHS tracker was prepared in advance, it helped in mitigating safety risks before the start of each activity. ´One Activity - One Supervisor´ principle was followed. b. Innovative work methods to achieve safety: (i)POD erection methodology. (ii)Purlin erection by using boom lift and crane. (iii)Canopy with roof sheeting erection. (iv)Strut pipe erection by using cranes and two boom lifts. (v)Painting touch-up at ground level and at height with help of boom lifts only. Good co-ordination with the civil contractor was maintained, and hence, no conflicts arose during the entire project completion. After installation of the MR-24® roof system, aluminium roof walkway with permanent roof lifeline system was installed to ensure safe access to the roof in future. Conclusion Detailed pre-execution EHS planning, effective use of risk mitigation techniques, rigorous implementation of EHS tracker, erection supervision by a dedicated construction safety team, use of boom lifts, SKY-WEB® II fall protection system, adoption of innovative construction techniques and Tata BlueScope Steel´s zero tolerance approach to safety violations, resulted in completion of the GE project safely. (Communication by the management of the company)