Wpa Sample Report

SAFETY AND HEALTH OFFICER EXAMINATION 3/2003 PAPER III PART 2 : WORKPLACE ASSIGMENT

HAZARDS IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL MEASURES

KUALA LUMPUR CONVENTION CENTRE PROJECT SUNWAY CONSTRUCTION BERHAD

Prepared by YATI AHMAD (NS2567)

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Table of Contents Contents

Page Number

Acknowledgements

v

1.

Abstract

1

2.

Introduction 2.1

The Company

2 –3

2.2

The Selected Project

4-5

2.3

Organization Chart

6

2.4

Activities and Work Processes

7

2.5

Work Environment

8

2.6

Job and Tasks

8

3.

Objective

4.

Methodology

9

4.1

Identifying Hazards

10 - 14

4.2

Technique Used to Assess and Evaluate

15 – 18

The Risks 4.3

Hazards Prioritisation

19

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Table of Contents Contents

5.

Page Number

Results 5.1

Hazards Listing

20

5.2

Critical Hazard and Its Effect to the Safety

21

and Health of Workers

6.

Recommendation 6.1

Control Measures

24

6.2

Programme Review

25

6.3

Conclusion

26

7.

References

27

8.

Appendices

28

Appendix I

Project Site Location

Appendix II

Built-up Area Plan

Appendix III

Company’s organisation chart.

Appendix IV

Kuala Lumpur Convention Centre Project Team Organisation Chart

iii

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Table of Contents Contents

Appendix V

Kuala Lumpur Convention Centre Site OSH Organisation Chart

Appendix VI

Summary of Master Work Programme for Kuala Lumpur Convention Center Project

Appendix VII

Photos for earthing installation at raft foundation area

Appendix VIII

Job Safety Analysis for Earthing Installation.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Acknowledgements

I would like to express my sincere appreciation and gratitude to Sunway Construction Berhad for giving me an opportunity to attend the Certificate of Safety and Health Officer Course organized by National Institute of Occupational Safety and Health (NIOSH).

I also wish to extend my thanks to Mr Phillip Varughese, Sr. Manager of Occupational Safety and Health in Sunway Construction Berhad for the advice, guidance and encouragement throughout my career in Occupational Safety and Health.

The special thanks also dedicated to Mr Bernard – Engineer of Pekat Technology Sdn Bhd, Mr Selva Rajah and Mr Rusmin Abd Ghani – Safety & Health Executives of Sunway Construction Berhad, Mr Michael Tan and Mr Beh Yen Fei – Planning Engineers of Sunway Construction Berhad, Mr Hung Siang Wei – Engineer of Sunway Engineering and the other colleagues of Kuala Lumpur Convention Centre Project, Sunway Construction Berhad for their support and encouragement throughout the preparation of this Workplace Assignment.

The last but not least, a warmest appreciation to my husband Mr Haidhir bin Kamarul Bahrin for the invaluable love, encouragement, caring and support.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project ____________________________________________________________________________________________________

1.

Abstract

This Workplace Assignment is a study to identify the hazards, assessing the risks and recommending the control measures for Earthing Installation at Raft Foundation at Kuala Lumpur Convention Centre Project, a project awarded to Sunway Construction Berhad.

The study has identified several hazards while installing the earthing system at raft foundation area in this project. Using the Risk Ranking Table, hazards for trip and fall was found as critical. This hazard may lead to an injury to the workers.

The slippery and unstable surface of rebar may contribute to the trip and fall hazard. To eliminate or minimise this hazard, the control measures recommended is to ensure good housekeeping. Proper safety shoes will assist in minimising the trip and fall hazard.

1

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

2.

Introduction 2.1

The Company Sunway Construction Berhad (SUNCON) was first incorporated as Sungei Way Quarry Sdn. Bhd in 1976. It was subsequently re- named Sungei Way Quarry and Construction Sdn. Bhd in March 1981 to reflect its growing involvement in the construction industry. During the Group’s corporate exercise in 1984, SUNCON changed its name to Sungei Way Construction Sdn. Bhd. In 1996, it was converted into public company, and it was listed in the main board of the Kuala Lumpur Stock Exchange (KLSE) on 12 June 1997. In line with the change of the Sunway Group, SUNCON acquired its present name on 13 December 1999.

SUNCON has, over the years, established itself as a reputable contracting concern having undertaken a wide range of turnkey building and civil engineering projects. Its track record features of buildings, roads, bridges, infrastructure works, etc. This was realized through the application of creative thinking, innovative methodology coupled with the synergistic diversification of the Sunway Group, undoubtedly one of Malaysia’s most dynamic and welldiversified conglomerates.

SUNCON is registered Class A Contractor with Pusat Khidmat Kontraktor. It is also registered as a Grade 7 entity with the Construction Industry

2

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Development Board of Malaysia. The Company’s clients range from governmental sectors to private organizations and individuals.

SUNCON aspires to be a progressive construction company both in the regional and international arena. The management of Occupational Safety and Health has been considered as an important key performance to the company. As an OHSAS 18001 certified company, SUNCON is committed to ensure the providing and maintaining a safe and healthy working environment by creating a corporate culture for the overall well-being of the employees and the community.

2.2

The Selected Project

3

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

This Workplace Assignment will study the hazard identification, risk assessment and risk control measures in one of the latest building construction activities done by SUNCON. The selected project worth RM 550 million, named as “Kuala Lumpur Convention Centre Project” is located in the Kuala Lumpur City Centre area.

The project is to be an international exhibition and convention centre to attract and conduct large international standard convention and related trade shows and exhibition.

The details of project : PROJECT TITLE Kuala Lumpur Convention Centre at Kuala Lumpur City Centre, Kuala Lumpur, Wilayah Persekutuan – Design, Construction and Completion of the Main Building Works LOCATION Bounded by Jalan Pinang & Jalan Kia Peng, the KLCC Metropolitan Park, the Mandarin Oriental Kuala Lumpur and the Menara Exxon-Mobil (Appendix I – Project Site Location)

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

BUILT-UP AREA & CAPACITY The Convention Centre is build into 4 sections i.e West Wing, Center Core, East Wing and Plenary Hall with 2 basement levels and 4 levels (GL – L4) above ground (Appendix II – Built-up Area Plan) CONTRACT DETAILS Contract Sum

:

RM 549.3 million

Contract Award

:

16th September 2002

Site Possession Date

:

17th September 2002

Contract Period

:

131 weeks

Sectional Completion

:

24th December 2004 (East Wing, West Wing & Centre Core)

Final Contract Completion

:

EMPLOYER

: Kuala Lumpur Convention Centre Sdn Bhd

PROJECT MANAGER

: KLCC Projeks Berhad

MAIN CONTRACTOR

: Sunway Construction Berhad

KEY TEAM MEMBER

: Taisei Corporation Japan

(TECHNICAL ADVISORY)

2.3

21st March 2005 (Plenary Hall)

Organisation Chart

5

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Appendix III describes the company’s organisation chart.

Appendix IV describes the Kuala Lumpur Convention Centre Project Team Organisation Chart

Appendix V describes the Kuala Lumpur Convention Centre Site OSH Organisation Chart

2.4

Activities and Work Processes

6

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Below is the common flow chart for SUNCON’s work processes

Tendering Processes Yes Design and Build ? No

Design and Development

Pre Construction and Planning

Procurement

Construction

Post Construction

Hand Over to Clients Ref : SUNCON Quality System – Product Realization As a construction company, details of work activities and schedule are vary from project to project. The details of work activities and schedule for the project also known as a Master Work Programme. This Master Work

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Programme will be planned by Planning Department and acts as a guidance for the project implementation.

Appendix VI describes the Summary of Master Work Programme for Kuala Lumpur Convention Center Project. With reference to this Summary, one of the current active jobs is Raft Foundation, which cover the activity of earthing installation. This Workplace Assignment had selected this activity to study the hazards identification, risk assessment and recommend the control measures for eliminating or minimising the risks.

2.5

Work Environment Kuala Lumpur Convention Center is a building construction works with 2 levels underground and 4 levels above ground.

2.6

Job and tasks For each job activity, Method Statement was established as guidance for the workers to do the tasks. Method Statement brief step by step the tasks and will be read together with Job Safety Analysis.

3.

Objectives

This Workplace Assignment objectives are

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

a. To identify the hazards in the Earthing Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project . b. To assess the risks that might raise from the hazards identified in the Earthing Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project . c. To recommend the control measures to minimise or eliminate the risks from the identified hazards in the Earthing Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project .

4.

Methodology 4.1

Identifying Hazards

9

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Hazards identification in the Earthing Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project was done with the implementation of Job Safety Analysis (JSA).

Job Safety Analysis is a tool to identify hazards, assess the risks and recommend the control measures for the work activities that will be done. The steps of JSA for identifying the hazards are by breaking down the job into its components parts in an orderly and chronological job sequences followed by identifying the hazards for each component. Then, the risks will be assessed and evaluated. The risk ranking will give the guideline of the urgency of action and control measures.

For Earthing Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project, the hazards identification steps were done by the discussion of sub contractor personnel (Operations), M&E Engineer and OSH personnel.

With reference to the Method Statement of Earthing Installation at Raft Foundation area, the jobs sequence for this activity are :

1. Installation of earth electrode (copper)

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

i.

Identify location

ii.

Drive in the copper bond earth electrode using hammer jet

iii.

Measure earth resistance and record

iv.

If earth resistance do not achieve desired value, insert rod coupling to joint first electrode to second electrode and drive in second electrode. Measure earth resistance again.

v.

If earth resistance achieve desired value, repeat step i to iv until all electrode planted.

2. Installation of horizontal earth cable (copper) i.

Identify location for laying cable (horizontal)

ii.

Lay cable along the routes

iii.

Repeat until all earth cable installed.

3. Exothermic Welding of horizontal earth cable to electrode i.

Insert the graphite mould and place both electrode and cable and ensure no gap between the jointing part

ii.

Place retaining disc and pour in welding powder

iii.

Use flint gun to ignite the starting powder

4. Installation of vertical cable via column reinforcement bar i.

tighten the vertical earth cable with wire tie to the : a.

raft foundation’s bottom horizontal rebar

b.

raft foundation’s upper horizontal rebar

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

c. ii.

column’s vertical rebar

vertical earth cable is wire tie to column rebar at 1m interval after the first welding point until the test point level or roof level interfacing point.

5. Installation of test point

Appendix VII describes photos for earthing installation at raft foundation area in Kuala Lumpur Convention Centre Project.

With the break down of the job into its component parts, the hazards can easily be identified as in this table: Job Sequences

Hazard Identification Potential Hazard Potential Risk

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

1. Installation of earth electrode (copper) i.

Identify location

Trip and fall

Minor injury

ii.

Drive in the copper bond earth electrode using hammer jet

Vibration

Diseases

iii.

Measure earth resistance and record

Trip and fall

Minor Injury

iv.

If earth resistance do not achieve desired value, insert rod coupling to joint first electrode to second electrode and drive in second electrode. Measure earth resistance again.

Vibration

Diseases

v.

If earth resistance achieve desired value, repeat step i to iv until all electrode planted.

2. Installation of horizontal earth cable (copper) i.

Identify location for laying cable (horizontal)

Trip and fall

Minor Injury

ii.

Lay cable along the routes

Trip and fall

Minor Injury

iii.

Repeat until all earth cable installed.

3. Exothermic Welding of horizontal earth cable to electrode i.

Insert the graphite mould and place both electrode and cable and ensure no gap between the jointing part

Crushed in between

Minor injury

ii.

Place retaining disc and pour in welding powder

- Smoke hazardous to health

Diseases

13

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

iii.

Use flint gun to ignite the starting powder

- Weld metal spew out

Major injury

- Explosion

Major injury

Hot material

Minor Injury

i. tighten the vertical earth cable with wire tie to the : - raft foundation’s bottom horizontal rebar - raft foundation’s upper horizontal rebar - column’s vertical rebar

- Trip and fall

Minor injury

- Crushed in between

Minor Injury

ii. vertical earth cable is wire tie to column rebar at 1m interval after the first welding point until the test point level or roof level interfacing point.

- Trip and fall

Major Injury

- Crushed in between

Minor Injury

- Trip and fall

Major Injury

- Crushed in between

Major Injury

4. Installation of vertical cable via column reinforcement bar

5. Installation of test point

Table 1 : Hazards Identification in the earthing installation at raft foundation area

4.2

Techniques Used to Assess and Evaluate the Risks

SUNCON has used the Risk Ranking Table to assess and evaluate the risks for the potential hazards that were identified in the job activities.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Probability Consequence 5

First Aid

1 2 Once in 2 Once years year 5 10

3 4 a Once in 6 Once a months month 15 20

5 Once a week 25

10 Minor Injury

10

20

30

40

50

15 Diseases

15

30

45

60

75

20 Major Injury / 20 Fracture 25 Fatality 25

40

60

80

100

50

75

100

125

Table 2 : Risk Ranking Table

Using this Risk Ranking Table, the risks for hazards identified in the earthing installation at the raft foundation area were assessed as below :

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Job Sequences

Hazard Identification Potential Hazard

Potential Risk

Risk Assessment Probabilit Consequences y

Risk Ranking

1. Installation of earth electrode (copper) vi.

Identify location

Trip and fall

Minor injury

3

10

30

vii.

Drive in the copper bond earth electrode using hammer jet

Vibration

Diseases

1

15

15

viii.

Measure earth resistance and record

Trip and fall

Minor Injury

3

10

30

ix.

If earth resistance do not achieve desired value, insert rod coupling to joint first electrode to second electrode and drive in second electrode. Measure earth resistance again.

Vibration

Diseases

1

15

15

x.

If earth resistance achieve desired value, repeat step i to iv until all electrode planted.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

2. Installation of horizontal earth cable (copper) iv.

Identify location for laying cable (horizontal)

Trip and fall

Minor Injury

3

10

30

v.

Lay cable along the routes

Trip and fall

Minor Injury

3

10

30

vi.

Repeat until all earth cable installed.

3. Exothermic Welding of horizontal earth cable to electrode iv.

Insert the graphite mould and place both electrode and cable and ensure no gap between the jointing part

Crushed in between

Minor injury

2

10

20

v.

Place retaining disc and pour in welding powder

- Smoke hazardous to health

Diseases

1

15

15

vi.

Use flint gun to ignite the starting powder

- weld metal spew out

Major injury

1

20

20

- explosion

Major injury

1

20

20

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

Hot material

Minor Injury

2

10

20

i. tighten the vertical earth cable with wire tie to the : - raft foundation’s bottom horizontal rebar - raft foundation’s upper horizontal rebar - column’s vertical rebar

- Trip and fall

Minor injury

3

10

30

- crushed in between

Minor Injury

2

10

20

ii. vertical earth cable is wire tie to column rebar at 1m interval after the first welding point until the test point level or roof level interfacing point.

- Trip and fall

Minor Injury

3

20

60

- crushed in between

Minor Injury

2

10

20

- Trip and fall

Minor Injury

3

10

30

- crushed in between

Minor Injury

2

10

20

4. Installation of vertical cable via column reinforcement bar

5. Installation of test point

Table 3 : Risk Assessment for Earthing Installation at Raft Foundation 18

Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

4.3

Hazards Prioritisation

The hazards identified in the job sequences of earthing installation at raft foundation were prioritised with reference to the Risk Assessment done in part 4.2.

The highest risk ranking resulted from the assessment was given the first number of prioritisation, followed with the second and third ranking. The list of prioritisation is as below:

No

Hazards

Risk Ranking

1.

Trip and fall

30

2.

Crushed in between

20

3.

Weld metal spew out

20

4.

Explosion

20

5.

Hot material

20

6.

Vibration

15

7.

Smoke hazardous to health

15

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

5.0

Results

5.1

Hazards Listing From part 4.0, the hazards identified in the earthing installation at raft foundation are :

No

Hazards

Category

1.

Trip and fall

Physical hazard

2.

Crushed in between

Physical hazard

3.

Weld metal spew out

Physical hazard

4.

Explosion

Physical hazard

5.

Hot material

Physical hazard

6.

Vibration

Health hazard

7.

Smoke hazardous to health

Health hazard

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

5.2

Critical Hazard and Its Effect to the Safety and Health of the

Workers

After assessment and prioritisation, trip and fall hazards was found as a critical hazard while doing earthing installation at raft foundation in Kuala Lumpur Convention Centre Project. This hazard score 30 points as a result of the risk ranking.

Workers are exposed to the trip and fall hazards as they are walking on the rebar. The rebar’s condition is quite slippery and is not a stable surface for walking.

Trip and fall hazard while walking or doing work on the rebar may lead to injury of the workers.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

6.0

Recommendation and Review

6.1

Control Measures The recommended control measures for hazards identified in the

earthing installation were based on the Risk Tolerance Guide and Urgency of Action Table. Risk Ranking 0 – 25

Description

26 – 50

Tolerance

51 – 75

Moderate

76 – 100

Substantial

Trival

Action

Times Scale & Urgency Relevant action is required Within 2 weeks and records need to be kept Controls are required. Within 1 week Consideration need to be given for an effective solution or improvement. Monitoring is required to ensure that the controls are maintained Efforts should be made to Within 4 days reduce the risk. Risk control measures should be implemented within a defined time period. Where the moderate risk is associated with extremely harmful consequences, further assessment may be necessary to establish more precisely the likelihood of harm as a basis for determining the need for improved control measures Work should not be started Within 1 day until the risk has been reduced. Measures shall be allocated to reduce the risk. Where the risk involves work in progress, urgent action shall be taken

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

101 – 125

Hazardous

Work shall immediately measures satisfactory

be stopped Immediately until all taken is

Table 4 : Risk Tolerance Guide and Urgency of Action

From the part 4.3, the risk ranking for the hazards identified in earthing installation at raft foundation activity were ranked in the Trival and Tolerance category.

The critical hazard i.e trip and fall is under Tolerance category and need an effective control measures and monitoring.

The recommended control measures for this hazard are:

No

Hierarchy

Control Measures Description

1.

Elimination

N/A

2.

Substitution

N/A

3.

Isolation

N/A

4.

Engineering Control

N/A

5.

Administrative Control

- Ensure housekeeping

6.

PPE

- Wear safety shoes

-

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

The control measures for the other hazards are listed in the Appendix VIII – Job Safety Analysis for Earthing Installation.

These recommended control measures will be used as training material for the workers. The training normally done in the Tool Box Briefing * session by the respective Supervisor.

* Tool Box Briefing : a short briefing session to workers of individual trades lead by their respective Supervisors.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

5.2

Program Review

The effectiveness of control measures implemented will be monitored through: a. Inspection or Audit result b. Incident and Accident.

Inspection or Audit may identify the inadequate or improper control measures. Some of the recommended control measures may not environmental-free or may produce uncomfortably to the workers. With the Inspection or Audit, the feedback or responses may be considered.

While there is any incident or accident, the control measures will be review to ensure its adequacy. The inadequate control measures may lead to an accident.

The review and revision of control measures will be done together of OSH personnel and respective Operational personnel (SUNCON staff or Sub Contractor Staff or both). The revised control measures once again will be brief to the workers through their Tool Box Briefing.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

6.3

Conclusions

In the earthing installation activity at raft foundation in Kuala Lumpur Convention Center Project, the most critical hazard identified is trip and fall. The control measures recommended will assist in eliminating or reducing the risk that occur in the work place. Therefore, the workers could do their works without or with a minimum risk to their safety and health.

The minimum manhours loss due to the accident can assist SUNCON much in ensuring on-time project hand-over to client. The benefits also goes to minimising the uninsured cost such as minimise staff turn over, minimise legal fees, minimise the loss time due to administrative matters by the relevant personnel and others. This will totally benefits SUNCON in ensuring its status as a reputable construction company.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

7.0

References

a. Sunway Construction Berhad, 2000, OSH Manual and Procedures b. Sunway Construction Berhad, 2002, Quality System Manual c. Sunway Construction Berhad, 2002, Project Occupational Safety and Health Programme – Kuala Lumpur Convention Centre Project d. Sunway Construction Berhad, 2002, Contractors Overall Schedule – Kuala Lumpur Convention Centre Project e. Sunway Construction Berhad, 2003, Method Statement for Earthing Installation (Electrical) - Kuala Lumpur Convention Centre Project f. Sunway Construction Berhad, 2002, Document Management System Database - Kuala Lumpur Convention Centre Project g. National Institute of Occupational Safety and Health, 1997, Safety and Health Officer Course Book.

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Workplace Assignment – Earthing Installation at Raft Foundation Area Kuala Lumpur Convention Centre Project

8.0

Appendices

28