HAZARDS AND THEIR SOURCES IN THE CEMENT INDUSTRY

Quarrying

The quarrying activity includes the drilling of bore holes, the filling up of explosives and the triggering of the explosives. Once this happens then the material is loaded and transported either to open storage piles or to the crushing area.

During the process of charging and ignition, the explosives are transported to the explosion area from the explosive storage facilities.

Hazards as a result of the Storage Transport and Use of explosives

The explosives are stored only in approved sites that have to comply with the requirements of relevant legislation. During explosives storage the main hazards are the following:

• Storing explosives and capsules in the same area
  
• Entry of unauthorised persons in the area
  
• Smoking or use of naked flame in the storage area
  
• Storage of other goods and equipment
  
• Bad housekeeping in and out of the warehouse.
  
• Inadequate distance (<10cm) between the containers and the warehouse wall
  
• Absence of boundaries and labelling
  
• Insufficient building maintenance (lighting, ventilation) with the possibility of concentration of humidity in the warehouse
  
• Execution of non approved maintenance work on the warehouse electrical wiring.
  
• Insufficient warehouse security
  
• Not following the FIFO (First In First Out) in the management of explosive stocks
  
• Using work or personal equipment that can create sparks (eg wireless mobile phones)
  

Hazards during the transport of the explosives are:

• The use of unauthorised vehicles
  
• The transport of explosives together with capsules as well as not keeping the necessary labelling during transport
  
• The carrying of passengers
  
• The unplanned stoppage
  
• The transport of explosives during unstable weather
  

Hazards during the use of explosives are:

• The Failure to implement the company rules and regulations
  
• The use of unauthorised explosives
  
• The Failure to use the approved explosion plan
  
• The existence of unexploded boreholes
  
• The Failure to prevent unauthorised person to approach the explosives area
  
• The transport of more than required explosives quantity
  
• The temporary storage of explosives at excessive temperatures (greater than 65 degrees C) or near naked flame
  
• The use of mobile telephony or wireless near explosives
  
• The use of unauthorised equipment when opening a hole in the explosives
  

During the filling up and triggering the explosives the main hazards are:

• The triggering the explosives by unauthorised personnel or outside the agreed timetable
  
• The insufficient warning prior to triggering
  
• The approach of other persons other than the person in charge near the explosion area following the triggering
  
• The failure to comply with the company procedures in case of untriggered explosives
  
• The failure to comply with the connecting procedures in case of electrical triggering
  
  

Hazards during the Bore holing process

During the bore holing process the basic hazards are:

• The moving parts of the bore holing machinery
  
• Falls from height
  
• Material falling from height
  
• Crushing of quarry table
  
• Hurling of material
  
• Presence of dust and noise
  
• Movement of earth moving equipment
  
  

Quarrying Operations - Risk Assessment – Protection Measures

Storage and transport of explosives

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The bore holing process

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Accident Prevention Check List

Accident Prevention Check List – Storing and Transportation of Explosives

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Accident Prevention Check List – Use of Explosives

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Accident Prevention Check List – The drilling process

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Crushing

Hazards

The hazards in the Crushing department focus on:

• The rotational movement and the movement of the parts of the crusher
  
• The exposure to noise and dust of the personnel responsible for the continuous control of the crusher
  
• The maintenance activities inside the crushing chamber
  
• The electrical problems
  
• The activities inside the hopper due to:
  
  • The operation of the feeder
    
  • The possible crushing of material
    
  • The approach of heavy goods vehicles for unloading material
    
• The movement of heavy goods vehicles:
  
  • Reversing of the vehicle into the hopper
    
  • Accident on personnel
    
• The inappropriate loading of material onto the heavy goods vehicles with the result that material is hurled from the vehicle as the material is transported.
  
  

Risk Assessment table – Protection measures

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Accident Prevention Check List

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Storage and material transport systems

Hazards and protection measures

The main hazards during the transportation and storing of material are:

• The airborne dust created during the storage of material
  
• The conveyor belts during their normal operation as well as during their maintenance
  

In order to reduce the risk from airborne dust:

• Material should not be stored at unacceptable heights
  
• To use dust suction systems
• To implement the necessary procedures for the routine cleaning of the settled dust
  

In material transport systems there are moving parts that are a constant source of hazard for any person working near these conveyors during normal operation or during the maintenance activities. For the safe operation of material transportation systems all the necessary guards are applied to isolate the moving parts. Additionally where personnel is working at a short distance from the guards, emergency stops are provided within short distance of these operators.

During the normal operation of the transportation systems:

• The removal of guards by unauthorised personnel must be prevented.
  
• Any maintenance work during the operation of the transportation systems must be avoided
  
• Removing material during the operation of the conveyors must be avoided
  
• The cleaning of overflows during operation must be avoided unless the cleaning is done by the conveyor operative.
  
• The use of unauthorised passageways either over or under the transportation systems must be avoided because there is the risk of personnel getting trapped by the conveyor or overflowing material can fall from height
  
• The overhead bridges must be clean in order to minimise the possibility of the tripping and falling of the personnel performing the checks on the conveyor belts
  
• Any intervention on the conveyor belt overload systems must be done by authorised personnel
  

During the maintenance activities of the material conveyor belts it is necessary:

• For the transportation systems to be secured so that accidental start ups are eliminated.
  
• To check that all guards have been put in place prior to commissioning and
  
• To Check that the maintenance work is completed and that all maintenance personnel have left the vicinity of the equipment
  
  

Risk assessment in the material storage and material transportation systems

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Accident Prevention Check List – Material Storage and Transportation

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The mill processes (milling, homogenisation, storing) - Raw material and cement mills

The milling plant consists of:

• The mill (cylindrical with ball bearings) and the separator
  
• The filters (The hazards and protection measures are described in chapter M01.02.06)
  
• The furnace for the production of hot gases for drying (for the hazards and protection measures please see the Chapter on fuels)
• The blowers for mixing the material after milling and before storage
  
• The exhaust blowers at the storage silos
  
  

Hazards and Protection measures during normal operation

The main hazards during normal operation of the mills mainly concern:

• The movement parts of machinery
  
• The falling of personnel from height of material
  
• The falling of material from height in case the protection ducting is blocked
  
• The hurling of mill parts
  
• The exposure to noise
  
• The exposure to dust
  

For the safe operation of the mills all the necessary guards must be in place in order to isolate the mechanical movement from contact with the operators. Additionally where operatives need to be near moving parts of machinery the necessary emergency batons must exist in case there is a need for to stop the machinery.

For the purpose of supervising the mills the operators are having to walk on specific platforms equipped with protective railing so that falls from height are prevented.

Due to the excess kinetic energy of material as it rotates and the continuous pounding of the material inside the mill there is a serious hazard from the frequent hurling of mill nuts. In order to minimise the risk of accidents it is necessary to wear the appropriate helmet as well as the periodic tightening of the of the nuts.

Within the milling area and the blowers homogenising area – storage, the employees are exposed to noise and dust. The sound level must be assessed and if in doubt it must be measured. The resulting corrective action first of all must involve the reduction of noise at source, then the isolation of noise and if then this is not possible to use the necessary and appropriate PPEs.

Due to the nature of work there is risk of dust being released to the atmosphere and if the dust stays airborne for a long time it creates short and long term breathing problems to the employees. A dust collection system must be used and employees must use the appropriate PPEs.

Hazards and protective measures during maintenance

The maintenance activities in the inside of the mills include:

• The maintenance of mill linings
  
• The replacement of the milling balls
  

As a result of the above activities a number of serious hazards are created for the workers at least as follows:

• Falls from height (from the mill platforms)
  
• Hurling of metallic fragments from the mills’ shell
  
• Work in confined spaces with insufficient ventilation
  
• Exposure to dust
  
• Exposure to High temperatures
  

Due to the nature of the hazards involved such high risk operations must necessarily be planned so that all the following preventive measures are adhered to:

• Securing of the plant in a place where there is easy access of the maintenance technician into the mill
  
• The maintenance activity must be conducted by authorised personnel
  
• The work must be carried out under continuous supervision
  
• Adherence to documented operating preventive procedures
  
• Assure the necessary ventilation of the work space
  
• Assure the reduction of temperature prior to access to the space
  
• The use of the appropriate PPEs that must include:
  
  • Special helmet equipped with eye protector
    
  • Safety belt connected to a tying rope
    
  • Special work ware and foot ware able to withstand thermal load
    
  • Heat retarding gloves
  • Special mask equipped with ventilating fun or connected to a central ventilation system
    
  • Portable torchlight RCD 15A
    
    

Risk Assessment in milling operations (Milling, Homogenisation, Storage) – Raw material and cement mills

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Accident Prevention Check List

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Silo cleaning operations - Raw material and cement

Hazards

The internal cleaning of silos is high risk and relatively frequent operation in the cement industry and for this reason all necessary preventive measures must be taken. The cleaning of the silo takes place whenever there is a problem in the extraction of material due to the blocking of the outlets from solidified material. In addition this happens when there is a problem with the ventilators and a result there is insufficient ventilation or homogenisation of the material in the Blending Sib.

The main hazards are focused in the following:

• Work in confined spaces
  
• Falling of personnel from the working platform
  
• Falling of material
  
• Exposure to dust
  
• Use of lifting equipment

Preventive safety measures

For such a high risk operation there must be a responsible supervisor for the silo cleaning. He is responsible to ensure that the following steps are followed:

• Firstly he must notify the silo operatives about the impending cleaning and to make sure that the feeding of material to the silo is stopped. This is done by decommissioning the relevant electrical motors, closing the silo inlet valves and by placing blind flanges for additional safety.
  
• Before the start of any cleaning activity the silo must be inspected from above using light (RCD 15A) which is lowered gradually downwards in order to observe:
  
  • If there are conglomerated masses of material on the silo walls and at what height
    
  • The quantity and distribution of material
    
  • To identify whether the level of material is over or under the silo side door
    
• Afterwards the cleaning of the walls from above is carried out, using the Givonet system which is done with the use of connecting the necessary piping without having to enter the silo
  
• The next step is to open carefully the side door. The door and the area around the door is cleaned using a dust suction system (DISAB) and with the use of aluminium piping with the operatives staying out side the silo.
  
• Once the supervisor has inspected and made sure that he has seen the bottom of the silo near the door and that no material masses are hang from the silo walls, then he gives the necessary instructions to start the Filter funs.
  
• All personnel entering the silo must be equipped with the following:
  
  • Dust mask type Ρ2 or Ρ3 due to the small size of dust particles inside the silo
    
  • Safety shoes
    
  • Safety glasses
    
  • Helmet
    
• Safety belt and harness connected to an appropriate rope leading outside of the silo. There must be at least two operatives outside the silo who in case of emergency will pool out the operative inside the silo. The supervisor is always nearby throughout the cleaning activity
  
• The cleaning of the silo is done either manually or using the suction system (DISAB). In both cases the cleaning is done peripherally in a downward spiral direction using the work platform
  
• The operator inside the silo must pay constant attention to the fact that he must step only on the clean bottom surface
  
• If the cleaning operation takes more than one day then it is the responsibility of the supervisor to inform daily the silo operators about the start and finish times.
  
  

Risk assessment – Cleaning of storage silos

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Accident Prevention Check List – Cleaning of storage silos

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The clinker production process

Hazards

The main hazards are focussed on the following

• Use of fuels
  
• Contact with superheated material
  
• Exposure to heat
  
• Exposure to noise
  
• Fall from height
  
• Mechanical hazards
  

The hazards due to the maintenance activities inside the clinker furnace may involve:

• Taking down and repairing of the composite inner lining
  
• Taking down material that adhered to the inner walls
  

In such activities other additional hazards must be included such as:

• Falling of material
  
• Insufficient ventilation
  
• Working in a confined space
  
• Thermal load
  
• Saturation of space with dust
  
• Moving part of transport machinery
  
• Use of high pressure pumps
  

With regards to the hazards of the operation and maintenance of the filters please refer to chapter 2.7.

Risk assessment in clinker production

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Accident Prevention Check List – Clinker production

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The filtering plant

Hazards and protection measures during normal operation

During the normal operation the main hazards associated with filters are:

• Falling of material on operatives due to blockage of the transportation system
  
• Operatives falling from height
  
• Exposure to dust
  
• Asphyxiation of operatives when inside the filters
  
• Electrical hazards (for electrostatic filters)
  
• Explosion due to the existence of increased concentration of CO in the case of coal dust
  

The main protective measures are:

• Never remove all the necessary safety devises such as barriers, guards, security of access doors etc
  
• The use of authorised personnel
  
• Always to follow the operating procedure for securing the electrostatic filter
  
• To follow the special operating instructions given for a particular type of work
  
• To with the safety instruction available at the work place
• To use the appropriate PPEs assigned to each operative
  
  

Hazards and protection measures during Filter maintenance

During the maintenance activities inside of the filter the following additional risks must be added such as:

• Dusty environment
  
• Accumulated material
  
• Insufficient ventilation
  
• High temperature
  
• Staggering and falling of operators
  
• Static electricity (electrostatic filters)
  

The main preventive measures necessary include:

• The removal all the accumulated material from the filter prior to entry
  
• The cleaning of the filter in a well ventilated environment
  
• The adequate earthing of the electrostatic filter
  
• The interruption of the compressed air supply (bag filters)
  
• The isolation of the mechanical movement of the filter as well as the material transportation system
  
• The review the dust levels prior to entry into the filter
  
• Opening the side doors so that the filter is cooled prior to entry
  
• The presence of supervisors outside the filter side doors so that they can act in case of an emergency
• The use the appropriate PPEs.
  
  

Risk assessment in filtering operations

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Accident Prevention Check List – Filter operation

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Loading and delivery of products

The loading and delivery equipment used includes the bag filling machine, the palletiser, the packing material warehouse, the finished goods warehouse and the truck silo filling facility

The main hazards associated with this area are:

• Mechanical hazards associated with the moving parts of machinery
• The movement of heavy lorries and goods transporting equipment (fork lifts delivery lorries, silo trucks etc)
  
• Fire in the packing material area or the wooden pallets
  
• Falls from height either material or people
  
• The hurling of dust or coming into contact with hot material
  
• Manual handling of loads
  
• Exposure to noise
  

The basic preventive measures for the reduction of the reduction of the consequences from the above hazards are:

• That guards or other collective safety barriers should never be removed (barriers, access doors)
  
• The adherence to the special operating instructions
  
• The adherence to the limited access rules as well as the road safety signage
  
• The use of the appropriate PPEs provided
  
• During maintenance activities the following hazards are added to the above list:
  
• Getting hit by compressed air or other hydraulic fluids
  
• Getting hit, crushed or trapped by machinery
  
• Dusty environment
  
• The basic preventive measures for the reduction of these additional associated risks are:
  
• The adherence to the standard operating procedures for the securing of the machinery prior to any maintenance activity
  
• The adherence any additional special instructions provided
  
• The use all the necessary PPEs provided
  
  

Risk assessment Bagging and loading for delivery of goods

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Accident Prevention Check List – Loading for delivery of goods

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Fuel strorage facilities

During the production of cement, the drying of raw materials and the production of clinker there is a need to consume large quantities of fuel that can be solid (coal and pet coke), liquid (heavy fuel oil) or gas.

For combustion (fire) to take place there is a need for three conditions to coexist:

• Presence of fuel
• Presence of oxygen
  
• Presence of thermal energy (heat)
  

If any one of the above three conditions is absent then the combustion does not take place (stops or does not start)

The start up of an unwanted fire may be due to employees not adhering to the company’s operating procedures, or due to the inappropriate maintenance of the fuel storage facilities.

The main hazards associated with the storage and use of fuel are:

• Explosion
• Fire
  
• Asphyxiation
  
• Creation of toxic waste (eg VOCs)
  

The basic sources of ignition are:

• The use of open flames near the storage areas
  
• The creation of hot spots during operation or maintenance of the tanks
  
• The self ignition of hot material
  
• The electrical discharge (thunderbolt, electrostatic charges, short circuits)
  

The basic preventive and protective measures for the reduction risks associated with the above are aimed towards the isolation or quick reduction of one of the three sources that create or cause the combustion namely the fuel quantity or oxygen or the presence of heat.

For this reason it is necessary:

• To adhere to the special safety operational instructions that specify that no smoking is allowed, nor the use of open flames near that fuel tanks and the distribution facilities
  
• To comply with the safety signage
• To make sure that the supply of electricity is switched off prior to any maintenance work.
  
• To make sure that the conditions for creating an explosive is removed prior to entering an empty tank or storage silo that previously contained fuel
  
• To routinely maintain all the storage facility’s health and safety equipment such as high pressure relief valves, the control valves, the equipment for protection against atmospheric discharge, the earthing equipment, the fire fighting and/ or neutralisation as well as the pipe isolation valves.
  
• To always use the appropriate PPEs
  

All hot working activities near the tanks should not be carried out unless authorised using the documented operational procedures.

Use of Coal

During the use of coal the main hazards are due to:

• The fact that coal can easily self ignite when exposed to the air
  
• The explosive characteristics of coal dust
  
• The production of highly toxic CO as a result of slow and incomplete combustion
  

In order to manage the risks with the above hazards it is necessary to:

• Avoid the storage of coal in enclosed areas or silos for a long time
  
• Control the temperature as well as the CO concentrations
  
• Inspect the outdoor storage facilities
  
• Make sure that the coal transportation pipes are always earthed so that any excess charges do not create an explosive condition
  
• Maintain the fire fighting/ neutralisation equipment in good order
  

Use of Fuel oil

During the use of Fuel Oil the main hazard is its flash point combustion temperature (>65C) which is relatively low.

In order to manage the risks associated with the use of fuel oil it is essential to:

• Ensure that the storage tanks are properly earthed and are equipped with the necessary facilities for use against atmospheric discharge
  
• Avoid fuel leaks during maintenance or unloading and to remove any possible discharges
  
• Make sure that the fire fighting and neutralisation facilities are properly maintained and in good operating condition
  
• Avoid the direct contact of fuel oil with human skin
  

Use of fuel gas

During the use of Gas the main hazard is its very low combustion temperature as well as the fact that the gas is transported under pressure

In order to manage the risks associated with the use of gas it is necessary to:

• Routinely check the integrity of the gas distribution network and always follow the special safety instructions in case of maintenance on the electrical safety devices
  
• Make sure that all authorised personnel involved, know and operate the emergency gas cut-off/ shat-down procedures
  
• The storage tanks and distribution network are properly earthed and are equipped with the necessary facilities for use against atmospheric discharge
  
  

Risk Assessment at the Fuel Storage Facilities

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Accident Prevention Check List Fuel storage

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Environment, work areas and passageways

The work areas must be constructed and adjusted according to the following parameters:

• The provision of adequate space for the activities carried out and the existence of entrances and exits
  
• The operational, ergonomic and safe positioning of work places and equipment
  
• The environmental conditions (Ventilation, air conditioning and light)
  
• The protection against physicochemical agents such as Noise, Dust, VOCs, toxic substances etc.

The safe keeping of the work place contributes greatly towards the prevention of accidents and work diseases

For this to be achieved there is a need to:

• Keep the passageways, floors and emergency exits free of any obstacles. To remove presently any material spilt on floors and escalators. If this is not possible the spillage area must be correctly labelled and protected.
  
• To remove and sharp corners or edges present either as a result of the building or the equipment and furniture.
  
• To close any permanent or temporary floor openings.
  
• To replace any barriers or guards when removed.
  
• To place the manual equipment and hand tools in safe place and out of the way.
  

In work areas where there is a risk of explosion or fire it is forbidden:

• To smoke or use of open flame
  
• To use tools and equipment that may create sparks or overheating
  
  

Accident Prevention Check List Environment, Work areas and Passageways

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Ladders and scaffolding

Hazards from the use of ladders

The common movable ladders must be made from strong material (equivalent to its use) with strong beams and non slippery steps. A ladder that is not functioning properly must be removed from use.

Another main hazard is the inherent instability of the ladder and for this reason the ladder must be stabilised appropriately or held down by personnel.

The ladders must be fit for use. The ladder must be at least 1 m higher than the work level.

The ladders must have the right inclination so that they are not too inclined or unstable. The inclination angle should be between 68 ο to 75ο , or inclination 1 (base) to 4 (height).

The double movable ladders should be less than 5 meters high and should have a solid method of restrain so that they do not open beyond the accepted limit.

For ladders equipped with extensions the full length of which reaches a maximum length of 12 meters must be stabilised at the top and the operative on the ladder must be supervised by a colleague at the ladder base. The operatives using such types of ladder must be trained and authorised in their use.

For the safe use of ladders it is necessary to:

• Check the condition of the ladders as well as the presence and adequacy of the anti slip material on the steps. In case that the floor surface is unstable or uneven there is a need to take the necessary measures that the ladder legs are stabled.
  
• Climb up and down the ladder with the face facing the ladder moving slowly and steadily holding the ladder with both hands.
  
• Avoid moving the body on the sides in order to reach away from the ladder or step further than the third step from the top.
  
• Handle only light tools always properly on a special belt so that the hands are always free to move up and down.
  
• Always use the helmet either on the ladder or working near.
  
• Avoid moving the ladder with a person on it.
  
• Have a colleague at hand to help the movement of people and vehicles whenever he ladder has to be placed in a passageway.
  
• Avoid letting two operators on the same ladder.
  
• Never leave tools on the top step of a double ladder.
  
• Never use the ladder as a scaffolding piece.
  
• Never work on metal ladders when the distance between the top of the ladder and the electricity supply lines is less than 5 meters.
  
  

Scaffolding hazards

For the execution of work at a height of more than 2m the scaffolding is the best method for managing the risk of falling from height. The use scaffolding itself on the other hand has the following hazards:

• The assembly and taking down of the scaffolding must be carried out by competent people equipped with the necessary harness and under the direction of a supervisor and according to the assembly instructions of the scaffolding manufacturer. Prior to the assembly of the scaffolding all parts and equipment are thoroughly checked.
  
• For scaffolding of more than 10m high they must be made of metallic piping.
  
• The scaffolding must comply with the legal requirements relating to the structure, assembly, use, the stability characteristics, the strength, the adequacy of the levels and floors, the access to the levels etc.
  
• The floor levels should be at least 0.6m. There is also a need for a barrier of at least 1m height.
  
• Metallic scaffolding must be protected against atmospheric discharges by having earthing every 20m along the perimeter.
  
• The maximum scaffolding load must be known and documented.
  
• The stable tying up on the building effectively secures the scaffolding from horizontal or seismic movements. Additionally it must be made sure that the scaffolding base is situated on a stable ground.
  

When working on scaffolding it is necessary to:

• Carry the hand tools only in special toolboxes and belts
  
• Lift material using appropriate lifting devices
  
• Avoid throwing tools and materials from height but by using the appropriate containers.
  
• Avoid leaving unsecured planks
  
• Secure safely the floor planks
  
• Avoid blocking the passageways with material
  
• Move from one level to the other using the appropriate ladders
  
• Avoid running or jumping on the level floors
  
• Avoid overloading the floors beyond the approved loading limit
  

Safety measures for movable scaffolding

• Avoid going beyond the accepted height
  
• Make sure that the wheels are blocked when stationary and secure the structure from possible tripping or movement
  
• Do not overload the scaffolding with material since there is the possibility of moving the centre of gravity upwards with increased possibility of tripping
  
• Do not move the scaffolding while it is used by operatives or contains materials
  
• Climb up or down the scaffolding from the inside of the scaffolding only
  
• Avoid approaching naked or isolated electrical supply lines either during assembly or the movement of the scaffolding
  
  

Accident Prevention Check List – Use of Ladders and Scaffolding

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Use of fork lifts

Hazards from the use of Fork Lifts

The more frequently reported accidents linked to the use of fork lifts are:

• Tilting of the fork lift
  
• Tilting of the load
  
• Hitting of goods or people
  

The main reasons for the increased risk when using fork lifts are:

• Lack of basic training
  
• Insufficient maintenance
  
• Insufficient visibility
  
• Inappropriate load
  
• In appropriate positioning of the load on the forks
  
• Excessive speed and negligent road safety culture
  

The fork lift drivers have the direct responsibility for the safe use of the vehicle. It is also the responsibility of the maintenance personnel to assure the reliable and proper functioning of the vehicle

Accident Prevention Check List- Use of Fork lifts (FL)

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Use of works vehicles (WV)

Hazards from the use of work vehicles

Other work vehicles are vehicles that are used to carry out other support activities within the cement factory. Such vehicles are earth moving equipment, loading trucks, mechanised broom etc.

Hazards can be generated from the use of such vehicles due to bad visibility, lack of training, not adhering to policies and instructions.

As a result of the above a number of accidents may arise that may involve the hitting or stepping of personnel, hitting other vehicles, hitting the buildings or facilities or the tilting of the vehicle itself due to inclined surfaces.

Accident Prevention Check List- Use of Work Vehicles (WV)

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Metal welding and cutting operations

Hazards in the Welding and Cutting Operations

The welding and cutting operations entail hazards such as:

• Hurling of hot particles
  
• Burns and fires
  
• Explosion
  
• Electrocution
  
• Exposure to hot and radiating sources
  
• Smoke and dangerous gases
  

In such activities the main protection and prevention measures are:

• The personnel undertaking these activities must have the necessary competence and authorisation
  
• The welding work areas must be isolated with the use of appropriate barriers so that glaring and hurling of hot particles to other areas is eliminated
  
• When welding is carried out at higher levels all the necessary measures must be undertaken so that other operatives working below are protected from hot particles. It is the responsibility of the welder to implement such protection.
  
• Remove all flammable material and waste material. If this is not possible then protective barriers must be used.
  
• During the welding or cutting operation there must be a fire extinguisher at hand and the operative must be competent in their use.
  
• Make sure that in case where welding is carried out indoors then a smoke suction system must be used appropriately placed.
  
• Prior to leaving the welding area the operative must check if as a result of the operation a hot spot has been created.
  
• Superheated welded areas must be protected so that they do not accidentally come in contact with skin.
  
• Welding cannot take place in areas where there is storage of flammable liquids such as petrol and paint.
  
• Always use the appropriate PPEs provided
  
  

Hazards from the use of Oxygen – Acetylene in welding and cutting operations

Α. General care of the cylinders
The operatives must make sure that:

• Oxygen or acetylene cylinders are handled with care whether full or empty and should not be thrown down, rolled or hit. Prior to their transportation valve caps must be used.
  
• The cylinders are placed in a special cylinder trolley in the upright position and tight up using chains or other strong means. The cylinders should not be transported with any other means other than the trolley provided. The use of magnetic lifting devices must be avoided
  
• The flexible piping is not pulled or bent violently and should be placed away from passageways and protected from damage from overstepping, hurled particles, hot surfaces or sharp edges.
  
• The stability means provided are used so that accidental displacement is avoided
  
• Following the use of the welding cylinders these are not be left unattended but placed in a predefined and safe area and not in the area of the rotary kiln.
  
• The cylinders are labelled according to an international labelling system. If the cylinders provided do not conform to the labelling these should be removed and returned to the supplier. It is forbidden to write on the cylinders.
  
• The oxygen cylinders are stored separately from the other cylinders. Also empty and full cylinders are stored separately. During storage the cylinders are safely secured in order to avoid their displacement and fall. They are not exposed to the sun or other sources of heat.
  
• Smoking and the use of open flames in the cylinders storage area is strictly prohibited. The area must be well ventilated.
  
• Prior to using the welding equipment this is checked thoroughly namely the valve, the piping and the burner. All piping must be equipped with a non return valve. The piping connections must be checked on a daily basis.
  
• On a routine basis the piping is checked for possible leaks using soap solution.
  
• No valve part is greased.
  
• Valves are operated using the appropriate tools provided.
  

Β Use of cylinders
The operatives must make sure that:

• The cylinders are always held upright and at a safe distance from the work area in a position that in case of emergency the operative can have unobstructed and quick access to the cut off valves.
  
• The burner is lit using a steady flame or a lighter without delaying especially indoors.
  
• The burner is cut off during momentary breaks in operation either to clean the burner or any other reason. The flame can be on only for short durations.
  
• The burner is placed in a predetermined position so that it does not come accidentally into contact with the piping the cylinders or other operatives.
  
• In case the burner catches fire the valves must be cut off readily. For this reason the appropriate key must be on the valve at all times.
  
• The flame is cut off by cutting the acetylene valve first and then the oxygen valve.
  
• At the end of the cylinders use the valves are cut off and the remaining gas in the piping should be let out.
  
• In case of cylinders overheating or ignition the emergency procedures are followed.
  
• The approved pressure settings are always used
  
• During the assembly of the piping to the cylinders and the burner the pipe colours are not confused
  
  

Arc welding operations

The welding and cutting operations can be a source of hazards such as:

• Hurling of hot particles
  
• Burns and fires
  
• Explosion
  
• Electrocution
  
• Exposure to hot and radiating sources
  
• Smoke and dangerous gases
  

The additional protection measures during arc welding operations are:

• The use of the protective arc welding mask provided to protect the eyes from the flash as well from ultra-violet rays. The cover should be able to protect the operative’s neck and face.
  
• The electrical connections as well as their condition on the welding machine should be checked on a daily basis. Additionally the condition of the electrodes and the welding pliers must be checked routinely
  
• The pliers that provide the contact should be connected on the body to be welded near the welding area.
  
• When welding on trucks with rubber wheels the truck should be earthed and extra care should be taken due to the existence of fuel and lubricants.
  
• The welding machine electricity supply lead should be protected from chemicals, mechanical trapping or water on the ground.
  
• During the arc welding operation the appropriate PPEs should be used that must include welding gloves, apron, shin protectors and safety shoes.
  
  

Accident Prevention Check List – Welding and metal cutting operations

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Use of manual hand tools

Hazards from the use of manual hand tools

The moving parts of manual hand tools must be guarded or equipped with safety devices in case they are hazardous.

The safety devices should never be removed unless required for their maintenance.

In such cases all necessary measures must be taken so that the risk of accident is reduced.

All guards or other safety devices must be replaced as soon as maintenance intervention has been carried out.

The general protection measures are:

• To never operate a manual hand tool if the worker is not competent in its use or authorised to do so.
  
• To always make sure that the hand tools are appropriate for the intended use and are correctly applied
  
• To never interfere with the hand tools’ electrical wiring unless you are competent to do so.
  
• To always plan your activities before using a hand tool
  
• To never touch its moving parts or try to stop it using your hands
  
• Never were loose or unbuttoned work wear or hanging sleeves, rings or ties because there is a serious risk of trapping. For the same reason any long hair must be contained within a hat
  
• To never approach any machine parts or the cutting area without the use of appropriate PPEs.
  
• To never leave the manual hand tool unattended and in operation
  
• To secure the hand tool before its cleaning or maintenance
  
• To never clean the work benches by using o compressed air, or by blowing, or by using bare hands. Use the appropriate brooms and spades provided. The grinding pieces may cause an accident
  
• To never talk to the operator during the use of hand tools
  
• To always use the appropriate PPEs for each type of operation
  
  

Hazards from the use of hand tools with electrical supply

The basic hazards are:

• Coming into contact with electricity
  
• Coming into contact with its moving parts
  
• The use of inappropriate parts and consumables
  
• The hurled particles, parts or machined parts
  

During the use of electrical hand tools such as drills and grinding wheels it is necessary to always check the environmental conditions such as:

• The working voltage and well as the supply sockets. The supply must correspond to the one labelled on the tool itself
  
• If the work area is wet or there is possibility of the tool coming into contact with metallic masses the voltage should not be more than 50V. Portable light must carry an appropriate RCD 15A
  
• Hand tools with double insulation must be preferred since they are safer
  
• Hand tools with power greater or equal to 1000W must be connected on the supply using a socket equipped with an RCD safety device
  
• The area must be appropriately lit and the passageways must be protected
  

For the safe use of portable electrical tools by the workers it is necessary to:

• Always place and remove the socket while the supply switch is off
  
• Always make sure that the socket is appropriate for use and that the earth leads are properly connected
  
• Never use equipment for which the electrical characteristics are not known or they do not carry a label form the manufacturer
  
• Make sure that all moving or hazardous parts are equipped with the necessary guards
  
• Be aware about where the supply lead is placed. It should not be placed on hot surfaces or sharp edges.
  
• Always check the integrity of the electrical connections when supply leads are extended. Always use sockets equipped with RCDs
  
• Always grab the tools from the handle in order to avoid accidental start-up of the tool
  
• Never lay down the supply leads since there is an increased risk of trips and falls
  
• Always use the appropriate PPEs
  
• In case the hand tool is not operating properly then it must be submitted for repair to the competent technicians rather than attempt to repair it yourself
  
  

Hazards from the use of hand tools driven using compressed air

The main hazards are created from:

• The use of compressed air
  
• The use of flexible piping
  
• The hurling of particles and cut parts during operation
  

For the safe use of hand tools driven using compressed air it is necessary to:

• Make sure that all moving parts are equipped with the necessary guards and other safety devices
  
• Check the integrity of the flexible hoses, the pressure level as well as the connections to be safe and dry
  
• Make sure that the piping does not impose an increased risk to the others
  
• Never bend the pipes in order to stop the flow of air or use the pipes as a puling rope to pull the tools
  
• Always use the supply valve whenever there is a need for die change or at the end of the
  
• Always remove the air from the supply line at the end of operation
  
• Always use the appropriate PPEs
  
  

Accident Prevention Check List – Use of Manual Tools

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Lifting machines and equipment

General hazards in the use of Lifting equipment

The main sources of hazards from the use of lifting equipment are:

• Crashing of the load or the lifting mechanism onto employees or operators within the working range of the lifting equipment
  
• Fall of the load to be lifted due to the failure of the lifting gear
  
• Fall of the load to be lifted due to insufficient or inappropriate securing of the load
  
• Tilting of the load during its transportation
  
• Crashing of the load on the building and as a result the tilting, release and crushing down of the load
  
• Electrocution as a result of lifting mechanism contacting overhead electricity supply lines
  

In general for the safe use of lifting equipment it is necessary:

• To allow their operation only by authorised and trained personnel having all necessary licenses
  
• To make sure that the operators comply with the necessary work instructions
  
• To make sure their safe operation and in particular the stopping mechanism, the breaks and the lifting lines
  
• To check on a routine basis the hook mechanism
  
• To always secure the load using the approved straps
  
• To always lift the load slowly upwards for several cm in order to make sure that the load is balanced and stable prior to its lifting
• To always avoid the lifting of loads overhead from working personnel. For this reason the lifting equipment must be equipped with a warning sound signal so that all persons are withdrawn from the area under the load.
  
  

Accident Prevention Check List – Use of Lifting equipment

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