occupation health safety practices at roofing rolling mills-uganda.pdf

8/11/2019 OCCUPATION HEALTH SAFETY PRACTICES AT ROOFING ROLLING MILLS-UGANDA.pdf

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i Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

8/19/2014 MAINSTREAMING OCCUPATIONAL HEALTH SAFETY

IN STEEL ROLLINGMILLS IN UGANDA

CASE STUDY: ROOFINGS ROLLING MILLS, NAMANVEFactory Phase 3

2014


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i Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

Table of Contents

Table of Contents ........................................................................................................................................... i

ABSTRACT ...................................................................................................................................................... v

ACRONYMS .................................................................................................................................................. vi

CHAPTER ONE ............................................................................................................................................... 1

INTRODUCTION ......................................................................................................................................... 1

1.0 BACKGROUND ..................................................................................................................................... 1

1.1 MAIN OBJECTIVE ........................................................................................................................... 3

1.2 SPECFIC OBJECTIVES ...................................................................................................................... 3

1.3 RESEARCH QUESTIONS ................................................................................................................. 3

1.4 SCOPE OF STUDY .......................................................................................................................... 3

1.4.1 Content scope .............................................................................................................................. 3

1.4.2 Time scope ................................................................................................................................... 3

1.4.3 Geographical scope ...................................................................................................................... 3

CHAPTER TWO .............................................................................................................................................. 4

LITERATURE REVIEW ................................................................................................................................. 4

2.0 Introduction .................................................................................................................................. 4

2.1 History of Occupational Safety ..................................................................................................... 4

2.2 OSH Practices in steel rolling mills ................................................................................................ 4

2.2.1 Cooperation ................................................................................................................................. 4

2. 2. 2 Competent authority .................................................................................................................. 5

2.2.3 Labour inspectorates ................................................................................................................... 6

2.2.4. Employers ................................................................................................................................... 6

2.2.5. Workers duties and rights .......................................................................................................... 9

2.3 Major causes of Accidents in Steel Mills. .................................................................................... 11


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ii Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

2.3.1 Ergonomic problems .......................................................................................................... 11

2.3.2 Noise .......................................................................................................................................... 12

2.3.3 Vibration .................................................................................................................................... 12

2.3.4 Heat exposure ............................................................................................................................ 12

2.3.5 Lasers ......................................................................................................................................... 13

3.6 Radioactive nuclides ......................................................................................................................... 14

2.3.7 Airborne Pollutants .................................................................................................................... 14

2.3.8 Dust and fumes .......................................................................................................................... 14

2.3.9 Work Equipment and Machinery UN Guarding. ........................................................................ 17

2.3.10 Falling Objects .......................................................................................................................... 18

2.4 Curbing Occupational Hazards in Steel Rolling Mills. ....................................................................... 18

2.4.1 The Role of Management........................................................................................................... 18

2.4.2 The Legal Requirement. ............................................................................................................. 19

2.4.3 The Financial or Cost Benefit Approach .................................................................................... 19

2.4.4 The Human Factors Approach ................................................................................................... 20

2.4.5 The Behavioural or Cultural Approach ....................................................................................... 20 2.4.6 What Are Managers Required To Do? ....................................................................................... 20

2.4.7 How should Management fulfil its Responsibilities? ................................................................. 21

2.4.8 The Role of Employees. .............................................................................................................. 22

2.4.9 The Role of the Safety Organization .......................................................................................... 22

2.4.10 The Role of Trade Union & Employee Representatives. .......................................................... 23

CHAPTER THREE

..........................................................................................................................................

24

METHODOLOGY ...................................................................................................................................... 24

3.1 Introduction ...................................................................................................................................... 24

3.3 Study Area ......................................................................................................................................... 24

3.4 Target population.............................................................................................................................. 24


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iii Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

3.5 Sampling Size .................................................................................................................................... 24

3.6 Data Collection Methods and Tools .................................................................................................. 25

3.6.1 Interview Method .......................................................................................................................... 25

3.6.2 Observation method .................................................................................................................. 25

3.6.3 Documentary Analysis ............................................................................................................... 25

3.7 Data Analysis Method ....................................................................................................................... 25

CHAPTER FOUR ........................................................................................................................................... 26

DISCUSSION AND PRESENTATION OF RESEARCH FINDINGS ................................................................... 26

4.0 INTRODUCTION ................................................................................................................................. 26

4.1 OSH PRACTICES IN ROOFINGS STEEL ROLLING MILLSFACTORY PHASE 3 ........................................ 26

4.1.1 Interview responses and Observed Safety Practices ................................................................. 26

4.1.2 Observations .............................................................................................................................. 29

4.2.1 Interview responses ................................................................................................................... 34

4.3 OSH MEASURES THAT CAN BE USED TO CURB OCCUPATIONAL HAZARDS AT ROOFINGS

ROLLING MILLS ........................................................................................................................................ 36

4.3.1 Interview responses/Observations ............................................................................................ 36

4.4 MAJOR CHALLENGES TO THE ESTABLISHMENT OF PROPER OSH STANDARDS IN ROOFINGS

ROLLING MILLSNAMANVE ..................................................................................................................... 37

4.4.1 Interview responses/observations............................................................................................. 37

CHAPTER FIVE ............................................................................................................................................. 38

SUMMARY, CONCLUSION AND RECOMMENDATIONS ........................................................................... 38

5.0 SUMMARY OF MAJOR FINDINGS ................................................................................................ 38

5.1 CONCLUSION ..................................................................................................................................... 39

5.3 SUGGESTIONS FOR FURTHER RESEARCH .......................................................................................... 41


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iv Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

LIST OF FIGURESFigure 1: Dressing code for operators and production supervisors ............................................................. 30

Figure 2:The Regenerative thermal oxidizer on Color Coating Line ........................................................... 31

Figure 3: Machines with rotating parts provided with guards ..................................................................... 31

Figure 4: Space between two machines, which is normally the working space .......................................... 32 Figure 5: Observation of lighting in a production section ........................................................................... 33

Figure 6: A worker using safety harness while at a height .......................................................................... 33

Figure 7: Some of the Safety signs at Roofings rolling mills ...................................................................... 34

LIST OF TABLES

Table 1: Interview responses on OSH practices in Factory Phase 3 ........................................................... 27

Table 2 : Observation on Major causes of accidents in Phase 3 .................................................................. 35

Table 3: Interview responses/observations on OSH measures that can be used to curb occupational

hazards at Roofings rolling mills-Factory Phase 3-Namanve ..................................................................... 36

Table 4: Interview responses on major challenges to establishment of proper OSH standards in Roofings

rolling mills-Namanve ................................................................................................................................ 37


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v Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

ABSTRACT

This report is a result of research into the state of Occupational safety and health of the iron and steel

industry in Uganda, comparing and contrasting the local practices for protection of workers with mainly

the Occupational safety and health act of Uganda, 2006 and International Labour Organization (ILO)

codes.

The purpose is to highlight ways to improve the Occupational safety and health of the steel workers

considering the existing resources and culture of work.

Data was collected through desktop research and on-field study during my daily work-supervision on the

plant/factory. Extensive review of relevant literature has also been done.

Overall, the Ugandan steel industry is growing fast due to the booming construction industry and

production of steel products is dominated by a number of players. A number of accidents in the industries

have been reported increasingly over the years.

A study carried out at Roofings rolling mills in Namanve showed that lack of proper training and absence

of a proper work permit system and personnel practices have held back improvement of Occupational

health and safety standards in the industry.


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vi Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

ACRONYMS

OSH Occupational Safety and health

ILO International Labour Organization

SRM Steel rolling mills

NIOSH National Institute for Occupational Safety and Health

WSA World Steel Association

OSHA Occupational safety and health association

EHS Environment Health and Safety

PPE Personal Protective Equipment

CCL Color Coating Line

CGL Continuous galvanizing line

PPPL Pick Push Pickling line

CRM Cold Rolling Mill

LOTO Lockout/Tagout


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1 Prepared by Kakama Gilbert ( Mech.Eng); Checked by Peterson Njuba ( Safety Officer) @RRMUganda

CHAPTER ONE

INTRODUCTION

1.0 BACKGROUND

According to World Steel Association, the world steel industry is a key driver of the worlds

economy and steel is at the core of a green economy, in which economic growth and environmental

responsibility work hand in hand. The steel industry believes that sustainable development must meet

the needs of the present without compromising the ability of future generations to meet their own

needs.

In 2011, world average steel use per capita was 215 kg and it has steadily increased over time as

Steel touches every aspect of our lives. No other material has the same unique combination ofstrength, formability and versatility. Steel is central to transport, housing, energy, agriculture, water

and infrastructure. (World Steel Statistical Yearbook, 2012)

According to the world steel association report of 2012, the industry directly employs more than two

million people worldwide, plus two million contractors and four million people in supporting

industries. Including industries such as construction, transport and energy, the steel industry is at the

source of employment for more than 50 million people (World Steel association report, 2012).

Further, the same report indicates the iron and steel industry is a heavy industry: in addition to the

safety hazards inherent in giant plants, massive equipment and movement of large masses of

materials, workers are exposed to the heat of molten metal and slag at temperatures up to 1,800C,

toxic or corrosive substances, air-borne contaminants and noise. Steel industry Spurred by trade

unions, economic pressures for greater efficiency and governmental regulations, the industry has

made great strides in the introduction of newer equipment and improved processes which afford

greater safety and better control of physical and chemical hazards. Workplace fatalities and lost-time

accidents have been significantly reduced, but are still a significant problem (ILO, 1992).

Steel making remains a dangerous trade in which the potential hazards cannot always be designed

out. Accordingly, this presents a formidable challenge to everyday plant management. It calls for

ongoing research, continuous monitoring, and responsible supervision and updated education and

training of workers at all levels (ILO, 1992).


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In 2005, ILO developed a code of practice for occupation safety and health for the iron and steel

industry to act as guidelines for different industrial settings to prevent the injuries related to steel

works.

In 2006, World steel Board made safety and health commitment accompanied by a set of six

principles aiming at preventing all injuries and illnesses in the industry.

The Ugandan steel industry has been growing at exceptional rates due to the booming housing and

construction sector in the region. The industry is dominated by a number of companies namely;

Madhivani group ran by East African Steel Corporation in Jinja, Steel Rolling Mills ltd under the

Alam Group of companies in Jinja established in 1987, Roofings Limited launched in December

1995, Sembule steel mills ltd, BM Technical Services in Mbarara, Tembo Steel Mills and Steel &

Tube Industries Ltd (STIL) and others, which have been operating steel mills in the country over the

years, first based on imported billets and later predominantly using scrap iron. (Uganda

manufacturing association)

Regardless of the effort put forward in the steel industry by World steel association, ILO and OSH

act, 2006 of Uganda, Steel rolling mills in Uganda have registered high incidences of occupational

injuries and fatalities as highlighted in the following paragraphs.

On 26 th September 2010, Yolisigira reported that two technicians had died and ten others were

seriously injured at Tembo steel rolling mills factory in Iganga when a continuous casting machine

section at the factory snapped causing the scrap metal melting chamber to topple over them.

On Friday 21 st July 2011, Ssejjoba and Musinguzi reported that the maintenance engineer had died in

a factory accident when he was crushed during the machine maintenance at roofing steel mills plant

in Namanve industrial area. (Published in The New Vision). It actually happened at Roofings

Limited.

On June 28 th 2011, Tuhairwa reported that a melting furnace had exploded at roofing steel mills plant

in Namanve industrial park and 6 technicians who were at the basement to ensure proper running had

sustained severe injuries on their faces, arms, heads and legs.

The above reported cases and situations have inspired this research to take this study. The case study

chosen is Roofings Rolling mills-Factory Phase 3 located in Namanve Industrial park-Uganda which

is a Cold Rolling Mill Complex.


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1.1 MAIN OBJECTIVE

To investigate how OSH can be mainstreamed at Roofings rolling mills to reduce on occupation

accidents.

1.2 SPECFIC OBJECTIVES

To determine the present OSH practices in Roofings rolling mills. To identify the major causes of occupational accidents at Roofings rolling mills. To identify OSH measures that can be used to curb occupational hazards at Roofings rolling

mills.

To examine the possible challenges to the establishment of proper OSH standards at

Roofings rolling mills.

1.3 RESEARCH QUESTIONS

What are the present OSH practices in Roofings rolling mills? What are the major causes of accidents at Roofings rolling mills? What OSH measures can be used to curb occupational hazards at Roofings rolling mills? What are the major challenges to the establishment of proper OSH standards Roofings

Rolling mills?

1.4 SCOPE OF STUDY 1 4 1 Content scope

The study was to investigate alternative approaches of improving on OSH measures at Roofings

rolling mills-Factory Phase 3.

1 4 2 Time scope

The study was carried out in the period of November 2012 to August 2014.

1 4 3 Geographical scope The case study was carried out in the production section of PPPL, CRM, and CGL & CCL. All are

production lines.


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CHAPTER TWO

LITERATURE REVIEW

2.0 Introduction

This chapter introduces scholarly work which has been done by other authors regarding occupationalsafety.

2.1 History of Occupational Safety

From its roots in Europe, as early as 16 th century the concept of Occupational Health has come a long

way only to become a very integral part of the world economy & society.

In 1906 in Milan an important step for the modern global workforce was the formation of the

Permanent Commission on Occupational Health later renamed the International Commission on

Occupational Health (ICOH). Today, ICOH is the world's leading international institution in the field

of occupational health with a membership of 2,000 professionals representing nearly 100 countries.

Occupational health & safety is not a new concept for India. The existence of the Indian Association

of Occupational Health (IAOH) for the past 60 years since 1948, is a testimony of the same.

2.2 OSH Practices in steel rolling mills

Operations in the iron and steel industry may expose workers to a wide range of hazards or

workplace activities or conditions that could cause incidents, injury, death, ill health or diseases. The

International Labour Organization (2005) identifies the following general duties to be followed by

both employers and employees to reduce on hazards at work places in the steel industry.

2 2 1 Cooperation

Measures for cooperation should be taken relating to the elimination or control of hazards or risks to

safety and health from the production of iron and steel. These measures should include the following;

i. Employers in discharging their responsibilities should cooperate as closely as Possible with

workers and/or their representatives.

ii. Workers should cooperate as closely as possible with their fellow workers and their

employers in the discharge by the employers of their responsibilities, and should comply with

all prescribed procedures and practices.


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iii. Suppliers should provide employers with all necessary information as is available and

required for the evaluation of any unusual hazards or risks to safety and health that might

result from a particular hazardous factor in the production of iron and steel.

2 2 2 Competent authority

The competent authority should, in the light of national conditions and practice and the provisions of

this code, in consultation with the most representative organizations of employers and workers

concerned to devise and maintain a national policy on OSH and consider making new, or updating

existing, statutory provisions for eliminating or controlling hazards in the production of iron and

steel. Statutory provisions should include regulations, approved codes of practice, exposure limits

and procedures for consultation and dissemination of information.

2 2 2 1 The competent authority should establish:

The systems including criteria for classifying substances that may be hazardous to health i.e. raw

materials, intermediary products, final products and by-products that are used and produced in the

production of iron and steel are;

i. Systems and criteria for assessing the relevance of the information required to determine

whether one of the substances listed above is hazardous.

ii. Requirements for marking and labeling substances provided for use in the production of iron

and steel, taking into account the need to harmonize such systems internationally.iii. Criteria for the information contained in the substance safety data sheets received by

employers.

iv. Systems and criteria for identifying safety hazards and appropriate risk control measures

relating to machinery, equipment, processes and operations used in the production of iron and

steel.

The competent authority should set out the necessary rules to determine these criteria and

requirements, but is not necessarily expected to undertake technical tasks or laboratory tests itself.

The competent authority should secure the enforcement of national laws and regulations concerning

the policy mentioned above through an adequate and appropriate system of inspection. The system of

enforcement should provide for corrective measures and adequate penalties for violations of national

laws and regulations concerning the policy. If justified on safety and health grounds, the competent

authority should;


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i. Prohibit or restrict the use of certain hazardous processes or substances in the Production of

iron and steel or require advance notification and authorization before such processes and

substances are used.

ii. Specify categories of workers who for reasons of safety and healthy are not allowed to use

specified processes or substances or are allowed to use them but only under conditions

prescribed in accordance with national laws or regulations.

The competent authority should ensure that guidance is provided to employers and workers to help

them comply with their legal obligations under the policy. The competent authority should provide

assistance to employers, workers and their representatives.

2 2 3 Labour inspectorates

Labour inspectorates should in a manner prescribed by national laws and regulations to periodically

carry out inspections in the presence of the employers and workers representatives and monitorcompliance with and enforce all relevant laws and regulations at iron- and steel-making facilities to

assist employers, workers and their representatives with respect to their occupational safety and

health responsibilities, duties and rights, monitor the safety and health requirements and performance

of comparable national or international iron and steel-making facilities to provide feedback for

further development and improvement of safety measures which participate in cooperation with the

recognized organizations of employers and workers, in formulating and updating safety rules and

measures to be adopted at national and enterprise levels.

Labour inspectors should in a manner prescribed by national laws and regulations to be competent to

deal with the safety and health issues associated with the iron and steel industry and be able to

provide support and advice to notify the employer, the workers concerned and their representatives as

well as safety and health committees of the findings of inspections for the implementation of required

remedial action and periodically determine whether an existing OSH management system or OSH

elements are in place, adequate and effective.

The authority, rights, procedures and responsibilities of labour inspectors should be communicated to

all affected parties.

2 2 4 Employers

Employers have a duty to protect and promote the safety and health of Workers were Employers

should comply with the measures to be taken regarding hazards or risks to safety and health from the

production of iron and steel including appropriate standards, codes and guidelines as prescribed,

approved or recognized by the competent authority. Employers should provide and maintain


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workplaces, plant, equipment, tools and machinery to organize work so as to eliminate or if this is

not possible control hazards and risks in the production of iron and steel and be consistent with

national laws and regulations.

Employers should set out in writing their respective programmes and arrangements as part of their

general policy in the field of OSH and the various responsibilities exercised under these

arrangements.

This information should be clearly communicated to their workers by oral, written or other suitable

means, commensurate with the ability of the workers.

Employers in consultation with workers and their representatives should make an assessment of the

hazards and risks to the safety and health of workers arising from the production of iron and steel

requesting and making effective use of the information provided by the supplier of equipment or

materials and from other reasonably available sources and take all necessary measures to reduce

exposure to eliminate or, if this not possible control risks to safety and health identified in the above

risk assessment.

In taking preventive and protective measures, the employer should address the hazardous factor or

risk in accordance with the hierarchy set out in Annex IV. If the employers, workers or their

representatives cannot agree, the issue should be referred to the competent authorities in accordance

with the rules; Employers should make the necessary arrangements to provide for regular

surveillance of the working environment and health surveillance adequate and competent supervision

of work and work practices.The application and use of appropriate control measures and the periodic review of their

effectiveness, education and training to managers, supervisors and workers about safety and health

representatives on issues relating to hazards in the production of iron and steel where necessary

arrangements. OSH measures should not involve any expenditure for the workers.

Employers should have in place arrangements to deal with accidents, dangerous occurrences and

incidents that may involve hazards or risks to safety and health from the production of iron and steel

and eliminate or control any risk to the safety and health of workers and thereby to the public and the

environment.

When an employer is also a national or multinational enterprise with more than one establishment,

the employer should provide safety and health measures relating to the prevention and control and

protection against injuries and risks to safety and health from the production of iron and steel to all

workers without discrimination. In accordance with the Tripartite Declaration of Principles


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concerning Multinational Enterprises and Social Policy (1977, Rev. 2000), in all countries in which

operate multinational enterprises should make available to their workers and to the representatives of

the workers at the facility and on request to the competent authorities.

The workers and employers organizations information on the standards related to injuries and risks

to safety and health from the production of iron and steel, relevant to their local operations which

they observe in other countries. The findings of any safety and health studies should be disclosed.

Employers should initiate and maintain a process of consultation and Cooperation with workers and

their representatives concerning all aspects of safety in the production of iron and steel specified in

this code, in particular as regards the measures of prevention and protection listed in paragraph

above. This process should be carried out within the framework of safety and health committees as

recommended by Convention No. 155 through another mechanism determined by the competent

authority or by voluntary agreements.

Employers should verify compliance with safety regulations and maintenance of safe working

techniques.

The care taken of machines and equipment, particularly any devices provided in the interest of safety

training in the use of and the care taken of personal Protective equipment (PPE) and the competence

of managers, supervisors and workers for their tasks. Managers and supervisors should implement

the enterprises safety and health policy including through the selection of safe equipment, work

methods and work organization and the maintenance of high levels of skill. They should endeavor to

reduce risks and hazards to safety and health in the activities for which they are responsible to as lowa level as possible. Managers and supervisors should ensure that workers receive adequate

information and training on safety and health regulations, policies, procedures and requirements and

satisfy themselves that this information is understood. Managers and supervisors should assign tasks

to their subordinates in a clear and precise way. They should satisfy themselves that workers

understand and implement the OSH requirements. Managers and supervisors should ensure that work

is planned, organized and Carried out in such a way as to eliminate possible risk of accidents and the

exposure of workers to conditions that may lead to injury or damage their health (see below for

guidance).In consultation with workers and/or their representative managers and supervisors should

assess the need for additional instruction, training and education of workers by monitoring

compliance with safety requirements.


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When managers or supervisors observe non-compliance with safety and health regulations or codes

of practice by any person, they should take corrective action immediately. If such action is un-

successful, the problem should be referred to a higher level of management immediately.

2 2 5 Workers duties and rights

Workers should have the duty to cooperate with the employer to achieve Compliance with the duties

and responsibilities placed on the employer pursuant to this code;cWhen workers or their

representatives observe non-compliance with safety and health regulations or codes of practice by

any person, they should take corrective action immediately then if such action is unsuccessful, the

problem should be referred to a higher level of management immediately Workers should have the

duty in accordance with their training, instructions and means given by their employers to comply

with prescribed OSH measures to take all steps to eliminate or control hazards or risks to themselvesand to others arising during the production of iron and steel including the proper care and use of

protective clothing, facilities and equipment placed at their disposal for this purpose.

Report forthwith to their immediate supervisor or safety and health representative any unusual

conditions at the workplace or affecting installations and equipment which they believe could present

a hazard or risk to their safety or health or that of other people arising from the production of iron

and steel and which they cannot deal with effectively themselves and cooperate with the employer

and other workers to permit compliance with the duties and responsibilities placed on the employer

and workers. Workers should participate in instruction and training programmes provided by the

employer or required by the competent authority and should demonstrate such acquired knowledge

and understanding of safety and health measures on the job.

Workers and their representatives should review the instruction and training programmes for

effectiveness where they determine that these programmes are ineffective they should make

recommendations to the employer to improve their effectiveness.

Workers should participate and cooperate in exposure monitoring and health surveillance

programmes required by the competent authority and/or provided by the employer for the protection

of their health.

Workers and their representatives should participate in the process of consultation and cooperate with

employers concerning all aspects of safety in the production of iron and steel specified in this code

and in particular as regards measures of protection and prevention listed below;


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(i) Workers and their representatives should have the right to be consulted regarding any hazards

or risks to safety and health from the production of non-ferrous metals.

(ii) Inquire into and receive information from the employer regarding any hazards or risks

tosafety and health arising from the production of iron and steel, including information from

suppliers. This information should be provided in forms and languages easily understood by

the workers.

(iii) Take adequate precautions in cooperation with their employer to protect themselves and other

workers against hazards or risks to safety and health from the production of iron and steel.

(iv) Request and be involved in the assessment of hazards and risks to safety and health from

hazardous factors to be conducted by the employer and/or by the competent authority. They

should also have the right to be involved in relevant control measures and investigations.

Workers and their representatives should be involved in the introduction and development of

workers health surveillance and should participate and cooperate with occupational health

professionals with their employers and with occupational health professionals in its implementation.

Workers should be informed in a timely, objective and comprehensible manner of the reasons for the

examinations and investigations relating to the safety and health hazards involved in their work

individually of the results of medical examinations including pre-assignment medical examinations

and of the respective health assessments. The results of medical examinations should be kept

confidential in accordance with national legislation and should not be used to discriminate against

workers.Workers should have the right to bring to the attention of their representatives, the employer or the

competent authority hazards or risks to safety and health arising from the production of iron and steel

to appeal to the competent authority if they consider that the measures taken and the means used by

the employer are inadequate for the purpose of ensuring OSH at work to remove themselves from

danger resulting from the production of iron and steel when they have reasonable justification to

believe that there is an imminent and serious risk to their safety and health and that of other people.

Such workers should inform their supervisor and/or safety and health representative immediately in

the case of a safety or health condition that places them at increased risk of harm to be transferred to

alternative work not exposing them to that increased risk if such work is available and if the workers

concerned have the qualifications or can reasonably be trained for such alternative work to receive

adequate compensation if the case referred to in above results in loss of employment. To be provided

with adequate medical treatment and compensation for occupational injuries and diseases resulting


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from the production of iron and steel and to refrain from using or to shut down equipment, a process

or to refrain from using a substance which can reasonably be expected to be hazardous if the relevant

information is not available to assess the hazards or risks to safety and health.

Workers who remove themselves from danger in accordance with the provisions should be protected

against undue consequences in accordance with national conditions and practice that Workers who

justifiably take those actions specified should be protected from unwarranted discrimination for

which there should be recourse in national laws and practice.

Workers and their elected safety and health representatives should receive appropriate education and

training and where necessary retraining in the most effective methods available for minimizing risks

to safety and health from the production of iron and steel in particular in those areas referred to in

Chapters of this code.

Women workers should have the right in the case of pregnancy or when breastfeeding to alternative

work not hazardous to the health of the unborn or nursing child where such work is available in order

to prevent exposure to hazards during the production of iron and steel to return to their previous jobs

at the appropriate time.

2.3 Major causes of Accidents in Steel Mills.

2 3 1 Ergonomic problems

This sub-chapter reviews the common causes of the potential OSH hazards in steel mills: Singleton,

W.T, ILO (2011) defined Ergonomics as the systematic study of people at work with the objective of

improving the work situation, the working conditions and the tasks performed. Ergonomic injuries

are those injuries caused by the presence of ergonomic risk factors , including: Awkward or sustained

postures, Forceful exertion or strain, Contact pressure, Exposure to vibration, Exposure to heat or

cold. (http://ergonomics.ucr.edu)

Despite the introduction of mechanization and assistive devices, manual handling of large, bulky

and/or heavy objects remains a frequent necessity and musculoskeletal injuries are common in steel

making.

Constant attention to housekeeping is necessary to reduce the number of slips and falls. Furnace

bricklayers have been shown to be at highest risk of work-related upper arm and low back problems.

The introduction of ergonomics into the design of equipment and controls (e.g., crane drivers cabs)

based on study of the physical and mental requirements of the job, coupled with such innovations as

job rotation and team working, are recent developments aimed at enhancing the safety, well-being

and performance of steel workers.(ILO Iron and steel encyclopedia,2011)


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2 3 2 Noise

Steel making is one of the noisiest industries, although hearing conservation programs are decreasing

the risk of hearing loss. The major sources include fume extraction systems,vacuum systems using

steam ejectors, electrical transformers and the arc process in electrical arc furnaces, rolling mills and

the large fans used for ventilation. At least half of noise exposed workers will be handicapped by

noise-induced hearing loss after as little as 10 or 15 years on the job. Hearing conservation

programmes include periodic noise and hearing assessments, noise control engineering and

maintenance of machines and equipment, personal protection, and worker education and training

which Causes the hearing loss other than noise include burns to the eardrum from particles of slag,

scale or molten metal, perforation of the drum from intense impulse noise and trauma from falling or

moving objects. A survey of compensation claims filed by Canadian steelworkers revealed that half

of those with occupational hearing loss also had tinnitus (McShane, Hyde and Alberti 1988).

2 3 3 Vibration

Potentially hazardous vibration is created by oscillating mechanical movements, most often when

machine movements have not been balanced, when operating shop floor machines and when using

such portable tools as pneumatic drills and hammers, saws and grindstones. Damage to vertebral

discs, low back pain and degeneration of the spine has been attributed to whole body vibration in a

number of studies of overhead crane operators (Pauline et al.1988). Whole body vibration can cause

a variety of symptoms (e.g. motion sickness, blurring and loss of visual acuity) which may lead to

accidents. Hand-arm vibration has been associated with carpal tunnel syndrome, degenerative joint

changes and Reynauds phenomenon in the finger tips (white finger disease), which may cause

permanent disability (Thomas and Clarke 1992).

2 3 4 Heat exposure

Heat exposure is a problem throughout the iron and steel industry, especially in plants located in hot

climates. Recent research has shown that, contrary to previous belief, the highest exposures occur

during forging when workers are monitoring hot steel continuously rather than during melting when

although temperatures are higher, they are intermittent and their effects are limited by the intenseheating of the exposed skin and by the use of eye protection (Lydahl and Philipson 1984). The

danger of heat stress is reduced by adequate fluid intake, adequate ventilation the use of heat shields

and protective clothing and periodic breaks for rest or work at a cooler task. Most people feel

comfortable when the air temperature is between 20C and 27C and when relative humidity ranges

from 35 to 60% when air temperature or humidity is higher people feel uncomfortable. Such


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situations do not cause harm as long as the body can adjust and cope with the additional heat. Very

hot environments can overwhelm the body's coping mechanisms leading to a variety of serious and

possibly fatal conditions.

In moderately hot environments, the body "goes to work" to get rid of excess heat so it can maintain

its normal body temperature. The heart rate increases to pump more blood through outer body parts

and skin so that excess heat is lost to the environment and sweating occurs. These changes impose

additional demands on the body Changes in blood flow and excessive sweating reduces a person's

ability to do physical and mental work. Manual work produces additional metabolic heat and adds to

the body heat burden. When the environmental temperature rises above 30C it may interfere with

the performance of mental tasks.

Heat can also lead to accidents resulting from the slipperiness of sweaty palms and to accidental

contact with hot surfaces. As a worker moves from a cold to a hot environment fogging of eye

glasses can briefly obscure vision presenting a safety hazard. Several studies comparing the heat

tolerances of men and women have concluded that women are generally less heat tolerant than men.

While this difference seems to diminish when such comparisons take into account cardiovascular

fitness, body size and acclimatization, women have a lower sweat rate than men of equal fitness, size

and acclimatization. Laboratory experiments have shown that women may be more tolerant of heat

under humid conditions but slightly less tolerant than men under dry conditions. The risk of heat-

related illness varies from person to person. A persons general health also influences how well the

person adapts to heat (and cold). Those with extra weight often have trouble in hot situations as the body has difficulty maintaining a good heat balance. Age (particularly for people about 45 years and

older), poor general health and a low level of fitness will make people more susceptible to feeling the

extremes of heat.Medical conditions can also increase how susceptible the body is. People with heart

disease, high blood pressure, respiratory disease and uncontrolled diabetes may need to take special

precautions. In addition, people with skin diseases and rashes may be more susceptible to heat.

(Occupational exposure to hot environments. Revised Criteria. Cincinnati, Ohio:National Institute for

Occupational Safety and Health, 1986).

2 3 5 Lasers

Lasers have a wide range of applications in steel making and may cause retinal damage at power

levels far below those required to have effects on the skin. Laser operators can be protected by sharp

focus of the beam and the use of protective goggles but other workers may be injured when they


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unknowingly step into the beam or when it is inadvertently reflected at them.(Health and safety

problems and patterns , www.ilo.org ).

3.6 Radioactive nuclides

Radioactive nuclides are employed in many measuring devices. Exposures can usually be controlled

by posting of warning signs and appropriate shielding. Much more dangerous, however, is the

accidental or careless inclusion of radioactive materials in the scrap steel being recycled. To prevent

this, many plants are using sensitive radiation detectors to monitor all scrap before it is introduced

into the processing. (Health and safety problems and patterns,www.ilo.org).

2 3 7 Airborne Pollutants

Steel workers may be exposed to a wide range of pollutants depending on the particular process, the

materials involved and the effectiveness of monitoring and control measures. Adverse effects aredetermined by the physical state and propensities of the pollutant involved the intensity and duration

of the exposure, the extent of accumulation in the body and the sensitivity of the individual to its

effects. Some effects are immediate while others may take years and even decades to develop.

Changes in processes and equipment along with improvement of measures to keep exposures below

toxic levels have reduced the risks to the workers. However, these have also introduced new

combinations of pollutants and there is always the danger of accidents, fires and explosions. (Health

and safety problems and patterns, www.ilo.org )

2 3 8 Dust and fumes

Emissions of fumes and particulates are a major potential problem for employees working with

molten metals making and handling coke and charging and tapping furnaces. They are also

troublesome to workers assigned to equipment maintenance, duct cleaning and refractory wrecking

operations. Health effects are related to the size of the particles, metals and aerosols that may be

adsorbed on their surfaces. There is evidence that exposure to irritant dust and fumes may also make

steelworkers more susceptible to reversible narrowing of the airways (asthma) which with over time

may become permanent (Johnson et al. 1985).Some of the different dusts and fumes in the steel rolling mills are as follows;

a) Silica

Exposures to silica, with resultant silicosis, once quite common among workers in such jobs as

furnace maintenance in melting shops and blast furnaces have been lowered through the use of other


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materials for furnace linings as well as automation which has reduced the number of workers in these

processes.

b) Asbestos

Asbestos once used extensively for thermal and noise insulation, is now encountered only in

maintenance and construction activities when formerly installed asbestos materials are disturbed and

generate airborne fibers. The long term effects of asbestos exposure include asbestosis, mesothelioma

and other cancers. A recent cross-sectional study found pleural pathology in 20 out of 900

steelworkers (2%), much of which was diagnosed as restrictive lung disease characteristic of

asbestosis (Kronenberg et al. 1991).

c) Heavy metals

Emissions generated in steel making may contain heavy metals (e.g., Lead, Chromium, Zinc, Nickel

and Manganese) in the form of fumes particulates and adsorbents on inert dust particles. They are

often present in scrap steel streams and are also introduced in the manufacture of special types of

steel products. Research carried out on workers melting manganese alloys has shown impaired

physical and mental performance and other symptoms of Manganese at exposure levels significantly

below the limits currently allowable in most countries (Wennberg et al. 1991). Shortterm exposure to

high levels of zinc and other vaporized metals may cause metal fume fever which is characterized

by fever, chills, nausea, respiratory difficulty and fatigue.

d) Acid mists

Acid mists from pickling areas can cause skin, eye and respiratory irritation. Exposure tohydrochloric and Sulphuric acid mists from pickling baths has also been associated in one study with

a nearly twofold increase in laryngeal cancer (Steenland et al.1988).

e) Sulphur compounds

The predominant source of Sulphur emissions in steel making is the use of high- Sulphur fossil fuels

and blast furnace slag. Hydrogen Sulphide has a characteristic unpleasant odor and short-term effects

of relatively low-level exposures include dryness and irritation of nasal passages and the upper

respiratory tract, coughing, shortness of breath and pneumonia. Longer exposures to low levels may

cause eye irritation while permanent eye damage may be produced by higher levels of exposure. At

higher levels, there may also be a temporary loss of smell which can delude workers into believing

that they are no longer being exposed.

f) Oil mists


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Oil mists generated in the cold rolling of steel can produce irritation of skin, mucous membranes and

upper respiratory tract, nausea, vomiting and headache. One study reported cases of lipoid

pneumonia in rolling mill workers who had longer exposures (Cullen et al. 1981).

g) Polycyclic aromatic hydrocarbons (PAHs)

PAHs are produced in most combustion processes in steelworks of coke making is the major source.

When coal is partially burnt to produce coke, a large number of volatile compounds are distilled off

as coal tar pitch volatiles including PAHs. These may be present as vapours, aerosols or adsorbates

on fine particulates. Short-term exposures may cause irritation of the skin and mucous membranes,

dizziness, headache and

nausea, while long-term exposure has been associated with carcinogenesis. Studies have shown that

coke-oven workers have a lung cancer mortality rate twice that of the general population. Those most

exposed to coal tar pitch volatiles are at the highest Nrisk. These included workers on the oven

topside and workers with the longest period of exposure (IARC 1984; Constantino, Redmond and

Bearden 1995). Engineering controls have reduced the numbers of workers at risk in some countries.

h) Other chemicals

Over 1,000 chemicals are used or encountered in steel making as raw materials or as contaminants in

scrap and/or in fuels as additives in special processes as refractorys and as hydraulic fluids and

solvents used in plant operation and maintenance. Coke making produces by-products such as tar,

benzene and ammonia others are generated in the different steel-making processes. All may

potentially be toxic, depending on the nature of the chemicals, the type, the level and duration of theexposures, their reactivity with other chemicals and the susceptibility of the exposed worker.

Accidental heavy exposures to fumes containing Sulphur dioxide and Nitrogen oxides have caused

cases of chemical pneumonitis. Vanadium and other alloy additions may cause chemical

pneumonitis. Carbon monoxide which is released in all combustion processes can be hazardous when

maintenance of equipment and its controls are substandard. Benzene, along with toluene and Xylene,

is present in coke-oven gas and causes respiratory and central nervous system symptoms on acute

exposure long-term exposures may lead to bone marrow damage, a plastic anaemia and leukemia.

i) Stress

High levels of work stress are found in the steel industry. Exposures to radiant heat and noise are

compounded by the need for constant vigilance to avoid accidents and potentially hazardous

exposures. Since many processes are in continuous operation, shift work is a necessity. Finally, there


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is the potent stressor of potential job loss resulting from automation and changes in processes, plant

relocation and downsizing of the workforce.

2 3 9 Work Equipment and Machinery UN Guarding

The use of work equipment including machinery, hand and portable power tools may result in

accidents, many of which are serious and some fatal. Of the many factors that can cause risk,

particular areas of concern include;

(i) A lack of guards or inadequate guards on machines which can lead to accidents caused by

entanglement, sheering, crushing, trapping, cutting, etc.

(ii) Failure to keep guards, safety devices, controls, etc., properly maintained and in place so

that the machines or equipment become unsafe.

(iii) The lack of appropriate safety systems, interlocks or other automatically functioning safety

devices and emergency stopping devices with insufficient strength of materials andinappropriate design of machines.

(iv) Failure to provide the right information, instruction and training for those using the

equipment.

(v) Hammers with broken or cracked handles, chisels and punches with mushroom heads, bent or

broken wrenches and wrenches with sprung jaws should not be used by Employees.

(vi) Most hand-held electrical power tools should be equipped with a dead man or Quick

release control, so that the power is automatically shut off wherever the Operator releases

the control.

(vii) All hand-held portable electrical equipment should have its frame earthed or be doubly

insulated and identified as such all power tools should be used with appropriate

shields,guards and attachments and in accordance with the recommendations of the

manufacturers.

(viii) Workers should be trained in the use of power tools and safety requirements.

(ix) Pneumatic power tools should be positively secured to the hose to prevent the tool From

becoming disconnected also a tool retainer should be used on tools to prevent the

attachmentfrom being disconnected.

(ix) Industrial robots present special hazards, in that they may move in unanticipated waysowing

to complex or faulty program.


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2 3 10 Falling Objects

Falling materials are a dangerous hazard. The employer should control the risk by adopting the

following measures to protect people working in any area where there is a danger of injury that may

be caused by falling material;

(a) Take all necessary steps to prevent materials or objects falling.

(b) Keep areas clean, in good working order and well maintained to prevent the

accumulation of process materials that could subsequently fall.

(c) Ensure the use of covered walkways or alternative safeguards such as safety nets.

(d) Schedules required overhead maintenance when there is the fewest number of people present

and ensure that access to the area is prevented by cordoning off all areas where there is a

potential risk from falling objects and providing warning signs and prevent access to areas

where there is a risk of falling objects, except in an emergency.

If people are required to have emergency access to any area where there is a danger of injury from

falling material, extreme caution should be taken to avoid injury. All such people should be provided

with appropriate PPE, such as hard hats, etc. The use of such equipment should be mandatory.

2.4 Curbing Occupational Hazards in Steel Rolling Mills.

Organizational arrangements to reflect the culture of the company are vital if safety

performance is to be improved. These will include:

2 4 1 The Role of Management

It has already been stated that management collectively and individually has the primary

responsibility for providing an effective management system that will ensure a safe and

healthy workplace. Traditionally this was generally accepted, but the motivation for it both

by companies and by individual managers has varied.

A number of negative and positive motivating factors or approaches can be identified in

determining the overall approach. All may have a part to play and in practice, a combination

of these factors is normally present rather than one factor in isolation.

2 4 1 1 The

Moral

Imperative

Employees should not suffer ill health or have accidents because of their work. Whilst there

is no doubt that it can be a complete motivating factor for certain individual managers, for an

organization as a whole, other factors have an important influence on the amount of attention

given to safety.


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2 4 2 The Legal Requirement

Essentially this approach has its focus on what the law requires and no more. Managers who

subscribe to this philosophy will fundamentally do only what is necessary to comply with the law.

Every initiative is judged on the basis of do we have to do this?. It implies an attitude of mind of

keeping the organization out of trouble by the enforcement of strict rules and procedures. While

compliance with the law is proper and, mostly, a necessary prerequisite for a safe working

environment, much more has to be done to improve the safety performance of an organization.

The legal approach in and of itself will not achieve the desired results and, at best, will tend to lead to

maintenance of the status quo. People at all levels have different perceptions of and respect for the

law. Moreover, an approach which is enforced from above (under penalty of legal sanction) has little

chance of succeeding in the modern world, at least to the extent required for world-class

performance.

2 4 3 The Financial or Cost Benefit Approach

Organizations that subscribe to this approach try to find a balance between, on the one hand, the

value of the resources necessary to obtain and maintain high standards of safety and, on the other

hand, the value of the benefits derived there from. While this may sound eminently reasonable and

economically sound the problem with this approach is that it is ultimately confronted with the

unanswerable question of What is the price of a human life?

The so-called total loss control system (TLC) is an example of a cost-benefit approach. According to

TLC, all accidents and incidents represent loss to the organization. All lossproducing events,

including damage without personal injury, are budgeted in monetary terms according to a standard

set of criteria. This cost is then written against a particular managers

budget as a means of motivating him to manage safety better in the future. The system has merit in

that it continuously focuses the managers attention on the management of safety, but it does little to

induce shop-floor employees to improve.

The maintenance of high safety standards requires adequate financial resources, but accidentsand

damage to equipment also cost money. It is easy to calculate the costs of, for example, training or

machine guarding, but is not so easy to calculate the costs of an accident.

Also, the costs of an accident to the organisation are generally absorbed into operating costs, and

rarely take into account the costs to the victims and their families, especially those costs that cannot

readily be quantified in monetary terms.


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2 4 4 The Human Factors Approach

Organizations that subscribe to the human factors approach focus on the various factors in the

workplace that influence compliance with safety procedures and practices. They take account of

human resource considerations and regard people as an important asset to the business that must be

protected against harm. Factors taken into account include influences created by the organization, the

actual work that people do and the personal circumstances of individuals.

The problem with this approach is that it does not go far enough in actually addressing the issue of

what motivates people, what effect this has on their attitudes and ultimately, how this influences their

behavior. In addition, it is essentially still a management-driven approach, with little regard for the

contributions that individual employees can make in a participative scheme. Despite its benevolent

intent, it still regards employees as business assets to be used by management in order to get

compliance.

2 4 5 The Behavioural or Cultural Approach

All the above approaches whether used together or in isolation have failed to produce the results in

safety performance that were sought. Companies making real progress in this field have turned their

attention to and concentrated increasingly on behavioural aspects. This is described in some detail in

the section of the report headed Motivation and Behaviour.

Whatever approach or combination of approaches is used, sound health and safety management is the

foundation upon which the companys approach to managing the business should be based. It

requires knowledgeable directors, managers, engineers and employees operating within a

management system that not only strives to eliminate accidents and control the risks, but also is

responsive to the needs of a business.

2 4 6 What Are Managers Required To Do?

Establish health and safety as a priority and core value of the company. Senior management

must be, and seen to be, active in living this priority and value.

Establish a world class health and safety programme. The programme must have a strong and

clear internal accountability system in which every employee has and understands his/herresponsibilities and his/her relative relationship to other corporate skill needs

(technical,operational and administrative).

Set health and safety workplace standards. Visibly demonstrate leadership in the implementation of managements programme

responsibilities.


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Integrate employee wellbeing into all activities (e.g. fitness and lifestyle issues) by providing

the necessary resources to support the development and implementation of theprogramme

and the business improvement plans

Ensure that competent people are identified to perform the required work. Reinforce that the proper management of health and safety contributes to improved cost,

anenhanced image and will lead to improved performance of the company, particularly in

reliability, quality and team development.

Negative reinforcement is the more traditional method employed in obtaining compliance,

but alone will not result in sustainable nor significant improvement. Positive

reinforcementapplies the principle of determining what you want people to do and

reinforcing them for doing that in a way that is meaningful to the employee. Applying this

technique properly in combination with negative reinforcement will result in not onlyimprovement in health and safety but will lead to a culture change. The consequences for all

employees of noncompliance with safety and occupational health policy must be tangible up

to and including loss of employment.

Recognition of good performance is clearly desirable. Set improvement targets. Integrate health and safety into every business decision.

2 4 7 How should Management fulfil its Responsibilities?

Ensure that the management system requires that all employees be held accountable for

meeting their responsibilities.

The incorporation of health and safety criteria in a management bonus and promotionsystem

is a very effective way of focusing attention on what is important.

Behave in a manner that is seen to be consistent with the companys values and the health

and safety programme. This applies to both work and home. This is a leadership issue and

one of the most powerful tools that can be used to change the way people work

Directly participate in the shop-floor evaluation of how people perform work. Reinforce

people for working safely and correct unsafe work.

Communicate health and safety issues as an integrated part of the business. Foster participation and involvement of all employees in improving health and safety

performance. Include health and safety performance as a key business indicator.

Ensure the right people are in the right jobs.


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2 4 8 The Role of Employees

Earlier in the report, attention was drawn to the importance of the role of all employees if Nprogress

is to be made in improving safety performance. This is particularly true as companies increasingly

recognise the importance of the behavioural aspects of safety. A good employee is a safe employee.

All employees should:

Work safely and follow rules and procedures.

Adopt a proactive rather than a reactive role to safety issues.

Accept responsibilities for safety - their own and their colleagues.

Report all unsafe situations.

Participate fully in the development of safe working practices in their widest sense.

Undertake the necessary training to ensure their competence.

Apply the training fully to all their activities.

Take part in the investigation of accidents, incidents and near misses.

Set an example in particular for the young and for new employees.

Support management in their efforts to improve safety performance generally.

Contribute to the work of safety committees where appointed.

2 4 9 The Role of the Safety Organization

It was stated in the earlier part of the report that any lingering ideas that safety within the company is

primarily the responsibility of safety management should be dispelled. The report continued,

however, that professional safety management has a vital and integral role to play in the companys

overall approach to safety. This section of the report amplifies that thinking. A safety organisation

is necessary for every company/plant. Every employee should be aware of that organisation and have

access to it if necessary.

The safety organisation should include experts from different disciplines within its ranks or

have access to them.

The methods by which the safety organization operates and its relationship to the rest of the

business operations should be clear.

These principles apply irrespective of the size of the plant, although the way the principles

are applied will vary.


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2 4 10 The Role of Trade Union Employee Representatives

Where unions are present in the work force, it is important to ensure that they are given a positive

role in the safety programme. In general, the primary responsibility for safety rests with the

management of the company.

However, in most jurisdictions the prevailing situation, legislated or otherwise, is for development of

a direct relationship and a shared involvement of the company management and its employees in

safety responsibilities. Where they are active, unions can play a significant role in maintaining and

improving safety standards.

There are as many variations in the role of unions in safety as there are individual companies and

unions. In some jurisdictions the role of unions is specified within applicable legislation, in others it

is expressed through the union taking on the role of the representative of employees in safety matters,

in others unions are not involved in safety at all and some combination of the above may apply in

other areas.

2 4 10 1 Positive Contributions

Where there are shared objectives at the local level and a clear and effective safety programme in

place, the role of unions in safety can be expected to be a supportive one. Unions can provide

effective positive reinforcement of company safety programmes: they can provide effective training

programmes, have on-the-floor practitioners as safety

representatives, be ambassadors for safety, participate in audits, accident investigations, risk

analysis and participate as members of safety committees. Positive pressure from unions can offset

employees perception of managers conflicts with non-safety priorities and generally, they have

effective channels to communicate with employees.

On a broader level, unions can be effective lobbyists with governments where there are companies

who are not living up to legislated health and safety obligations or where such roles and regulations

are not effective in the work place. In addition, unions may assist to keep health and safety issues at

the forefront of management attention both on an ongoing basis and periodically in the process of

contract negotiation.


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CHAPTER THREE

METHODOLOGY

3.1 Introduction

This chapter describes the methods that were used in the study. It includes the research design, area

of study, target population, population sample, research instruments used, research procedure and

analysis of data.

3.2 Research design

In this study, the research was based on a descriptive design. According to Kombo and Tromp

(2006), a descriptive study design is used to describe the state of affairs, as it exists. It can be used

when collecting information about peoples attitudes, opinions, habits or any of the variety of issues.

The researcher chose this design because he wants to develop a general understanding of the problem

in question. It followed both a qualitative and quantitative approach.

3.3 Study Area

This research was carried in Factory Phase 3 because of the experience I have attained since the

construction stage to commissioning stage and where I spend most of my working hours.

3.4 Target population

The study population comprised of safety officers, production team and maintenance team. These

respondents were targeted because they are the major stakeholders in occupational safety and healthy

in these workplaces. This selection enabled the researcher to get crucial data about the study

problem.

3.5 Sampling Size

Random selection of people was done


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3.6 Data Collection Methods and Tools

The collection of data for this study took two forms, namely; Field data and secondary data.

Collection of field data involved the use of an interview and an observation checklist to gather

information from the selected respondents in different production lines. Collection of secondary data

involved the review of official documents such as files, memos, textbooks, journals, magazines,

resource centers, and internet.

3.6.1 Interview Method

In this method, face to face interviews between the researcher and the correspondents were carried

out. An interview guide with open ended questions was used to collect data from the respondents.

This ensured accurate information and allowed deeper investigation into the study problem. It also

enabled the researcher to observe nonverbal communication.

3 6 2 Observation method Information was also gathered through observations. This was done as interviews were being carried

out at the premises. Bhandarkar, Wilkinson, &Laldas cited in Odiya (2009 p.169) notes that

observations may be structured or unstructured. Structured observations are characterised by well-

defined units to be observed, information to be recorded and how to observe it. For this study, a well-

structured observation checklist was used. The observations took place in such a way that the people

who were being observed were not aware because if they were, naturally they change behaviour.

Photos were also taken to capture safety practices.

3 6 3 Documentary Analysis

This information was collected from text books, magazines, journals, and internet, newspapers, files,

memos, and resource centres. This supplemented on data which had been gathered from the primary

sources.

3.7 Data Analysis Method

Thematic content analysis was used as the main analysis strategy. Key findings were transformed

into themes for analysis and presentation of data. Thematically, study findings were first coded and

consequently arranged in themes and sub-themes.


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CHAPTER FOUR

DISCUSSION AND PRESENTATION OF RESEARCH FINDINGS

4.0 INTRODUCTION

This chapter presents the discussion of findings of the study in line with the objectives of the study as

presented in chapter one.

4.1 OSH PRACTICES IN ROOFINGS STEEL ROLLING MILLSFACTORY PHASE 3

This section presents the discussion of findings on OSH practices in Roofings Steel rolling mills-

Factory Phase3-Namanve, presented in themes derived from interview responses and observations

from other employees shown in the following table;

4 1 1 Interview responses and Observed Safety Practices

CATEGORIES PARTICIPANT RESPONSESOHS Management There is an Environment Health and Safety(EHS)

department responsible for OSH There is an EHS policy in Roofings rolling mills-Namanve There is a budget for safety department to address safety

issues There are safety audits carried out at the plant

Handling/Lifting ofObjects

Workers handle light objects Lifting of Heavy objects is done by use of forklifts and

E.O.T cranes Work Environment There are dedicated cleaners on who clean floors

CCL section has Regenerative thermal Oxidizer and exhaust fans Machines are well spaced to ease work Working environment is provided with enough light to

enable good visibility


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Safety equipment There are fire extinguishers, fire detectors and fire alarms at strategic locations There is a fire alarm system installed Water spray points in the acid regeneration plant and Push/pull pickling lines in case of spillages on people

Signage/sign posts Machines are labelled with caution signs Emergency exists are labelled Well demarcated walk ways of more than 1.5M from

running machines Entry points to areas which require PPE are labelled with

appropriate signs There are sign posts indicating hot surfaces and corrosive

LiquidsPersonal protective

equipment (PPE) Helmets are provided for head protection Ear muffs/plugs are provided for protection against high noise

levels Cotton and plastic gloves are availed to workers Safety boots for foot protection Goggles are used for eye protection Nose masks are provided for protection against dust and

fumes Safety harness is provided for work at height Coveralls are provided to staff

Machines/Equipment Latest technology is used in rolling operations All rotating machines are provide with guards All equipment and machines that run the hydrochloric system are

sealed and made of acid resistant materials i.e. PPH, granite molds Training Orientation of new workers about companys safety policy New workers are trained on how to operate machines before

assigning jobs Safety workshops are carried out but rarely in a year and are

not compulsory First aid There are first aid kits at all production lines and

departments First Aiders have been trained There is a clinic on site with trained medical personnel

Table 1: Interview responses on OSH practices in Factory Phase 3

OSH Management

The interview responses in Table 1 show that there is EHS management responsible for overseeing

OSH practices at Roofings rolling mills-Namanve. This is in line with the role of management as

stipulated by ILO, 2005 and OSH act of Uganda, 2006 that employers should set up OSH

management systems at work places as a means of reducing injuries and accidents.

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