Occupation Health Safety Practices at Roofing Rolling Mills-Uganda PDF

i
PreparedbyKakamaGilbert(Mech.Eng);CheckedbyPetersonNjuba(SafetyOfficer)@RRMUganda
8/19/2014

MAINSTREAMING OCCUPATIONAL HEALTH &SAFETY
IN STEEL ROLLINGMILLS IN UGANDA

CASE STUDY: ROOFINGS ROLLING MILLS, NAMANVE
Factory Phase 3

2014
i
TableofContents
TableofContents...........................................................................................................................................i
ABSTRACT......................................................................................................................................................v
ACRONYMS..................................................................................................................................................vi
CHAPTERONE...............................................................................................................................................1
INTRODUCTION.........................................................................................................................................1
1.0BACKGROUND.....................................................................................................................................1
1.1 MAINOBJECTIVE...........................................................................................................................3
1.2 SPECFICOBJECTIVES......................................................................................................................3
1.3 RESEARCHQUESTIONS.................................................................................................................3
1.4 SCOPEOFSTUDY..........................................................................................................................3
1.4.1Contentscope..............................................................................................................................3
1.4.2Timescope...................................................................................................................................3
1.4.3Geographicalscope......................................................................................................................3
CHAPTERTWO..............................................................................................................................................4
LITERATUREREVIEW.................................................................................................................................4
2.0 Introduction..................................................................................................................................4
2.1 HistoryofOccupationalSafety.....................................................................................................4
2.2 OSHPracticesinsteelrollingmills................................................................................................4
2.2.1Cooperation.................................................................................................................................4
2.2.2Competentauthority..................................................................................................................5
2.2.3Labourinspectorates...................................................................................................................6
2.2.4.Employers...................................................................................................................................6
2.2.5.Workersdutiesandrights..........................................................................................................9
2.3 MajorcausesofAccidentsinSteelMills.....................................................................................11
ii
2.3.1 Ergonomicproblems..........................................................................................................11
2.3.2Noise..........................................................................................................................................12
2.3.3Vibration....................................................................................................................................12
2.3.4Heatexposure............................................................................................................................12
2.3.5Lasers.........................................................................................................................................13
3.6Radioactivenuclides.........................................................................................................................14
2.3.7AirbornePollutants....................................................................................................................14
2.3.8Dustandfumes..........................................................................................................................14
2.3.9WorkEquipmentandMachineryUNGuarding.........................................................................17
2.3.10FallingObjects..........................................................................................................................18
2.4CurbingOccupationalHazardsinSteelRollingMills........................................................................18
2.4.1TheRoleofManagement...........................................................................................................18
2.4.2TheLegalRequirement..............................................................................................................19
2.4.3TheFinancialorCostBenefitApproach....................................................................................19
2.4.4TheHumanFactorsApproach...................................................................................................20
2.4.5TheBehaviouralorCulturalApproach.......................................................................................20
2.4.6WhatAreManagersRequiredToDo?.......................................................................................20
2.4.7HowshouldManagementfulfilitsResponsibilities?.................................................................21
2.4.8TheRoleofEmployees...............................................................................................................22
2.4.9TheRoleoftheSafetyOrganization..........................................................................................22
2.4.10TheRoleofTradeUnion&EmployeeRepresentatives...........................................................23
CHAPTERTHREE..........................................................................................................................................24
METHODOLOGY......................................................................................................................................24
3.1Introduction......................................................................................................................................24
3.3StudyArea.........................................................................................................................................24
3.4Targetpopulation..............................................................................................................................24
iii
3.5SamplingSize....................................................................................................................................24
3.6DataCollectionMethodsandTools..................................................................................................25
3.6.1InterviewMethod..........................................................................................................................25
3.6.2Observationmethod..................................................................................................................25
3.6.3DocumentaryAnalysis...............................................................................................................25
3.7DataAnalysisMethod.......................................................................................................................25
CHAPTERFOUR...........................................................................................................................................26
DISCUSSIONANDPRESENTATIONOFRESEARCHFINDINGS...................................................................26
4.0INTRODUCTION.................................................................................................................................26
4.1OSHPRACTICESINROOFINGSSTEELROLLINGMILLSFACTORYPHASE3........................................26
4.1.1InterviewresponsesandObservedSafetyPractices.................................................................26
4.1.2Observations..............................................................................................................................29
4.2.1Interviewresponses...................................................................................................................34
4.3 OSH MEASURES THAT CAN BE USED TO CURB OCCUPATIONAL HAZARDS AT ROOFINGS
ROLLINGMILLS........................................................................................................................................36
4.3.1Interviewresponses/Observations............................................................................................36
4.4 MAJOR CHALLENGES TO THE ESTABLISHMENT OF PROPER OSH STANDARDS IN ROOFINGS
ROLLINGMILLSNAMANVE.....................................................................................................................37
4.4.1Interviewresponses/observations.............................................................................................37
CHAPTERFIVE.............................................................................................................................................38
SUMMARY,CONCLUSIONANDRECOMMENDATIONS...........................................................................38
5.0 SUMMARYOFMAJORFINDINGS................................................................................................38
5.1CONCLUSION.....................................................................................................................................39
5.3SUGGESTIONSFORFURTHERRESEARCH..........................................................................................41
iv
LIST OF FIGURES
Figure1: Dressing code for operators and production supervisors.............................................................30
Figure2:TheRegenerativethermaloxidizeronColorCoatingLine...........................................................31
Figure3: Machines with rotating parts provided with guards.....................................................................31
Figure4: Space between two machines, which is normally the working space..........................................32
Figure5: Observation of lighting in a production section...........................................................................33
Figure6: A worker using safety harness while at a height..........................................................................33
Figure7: Some of the Safety signs at Roofings rolling mills......................................................................34

LIST OF TABLES

Table1:Interview responses on OSH practices in Factory Phase 3...........................................................27
Table2: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
Table4:Interview responses on major challenges to establishment of proper OSH standards in Roofings
rolling mills-Namanve................................................................................................................................37

v
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.

vi
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

1
CHAPTERONE
INTRODUCTION
1.0BACKGROUND
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 of
strength, 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).
2
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 J inja, Steel Rolling Mills ltd under the
Alam Group of companies in J inja 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 26th 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 21st J uly 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 J une 28th 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.
3

1.1 MAINOBJECTIVE
To investigate how OSH can be mainstreamed at Roofings rolling mills to reduce on occupation
accidents.
1.2 SPECFICOBJECTIVES
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 RESEARCHQUESTIONS
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 SCOPEOFSTUDY
1.4.1Contentscope
The study was to investigate alternative approaches of improving on OSH measures at Roofings
rolling mills-Factory Phase 3.

1.4.2Timescope
The study was carried out in the period of November 2012 to August 2014.
1.4.3Geographicalscope
The case study was carried out in the production section of PPPL, CRM, and CGL & CCL. All are
production lines.

4
CHAPTERTWO
LITERATUREREVIEW
2.0 Introduction
This chapter introduces scholarly work which has been done by other authors regarding occupational
safety.
2.1 HistoryofOccupationalSafety
From its roots in Europe, as early as 16th 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 OSHPracticesinsteelrollingmills
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.
2.2.1Cooperation

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.
5
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.

2.2.2Competentauthority
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.
2.2.2.1Thecompetentauthorityshouldestablish:

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;
6
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.
2.2.3Labourinspectorates
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 monitor
compliance 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
7
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
8
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 low
a 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.
9
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.Workersdutiesandrights
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 themselves
and 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;
10
(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
11
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 MajorcausesofAccidentsinSteelMills.
2.3.1 Ergonomicproblems
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)
12
2.3.2Noise
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).
2.3.3Vibration
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).
2.3.4Heatexposure
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 intense
heating 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
13
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).
2.3.5Lasers
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
14
unknowingly step into the beam or when it is inadvertently reflected at them.(Health and safety
problems and patterns , www.ilo.org).

3.6Radioactivenuclides
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).
2.3.7AirbornePollutants
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 are
determined 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)
2.3.8Dustandfumes
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 (J ohnson 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
15
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 to
hydrochloric 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
16
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 the
exposures, 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
17
is the potent stressor of potential job loss resulting from automation and changes in processes, plant
relocation and downsizing of the workforce.
2.3.9WorkEquipmentandMachineryUNGuarding.
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 and
inappropriate 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.
18
2.3.10FallingObjects
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.
2.4CurbingOccupationalHazardsinSteelRollingMills.
Organizational arrangements to reflect the culture of the company are vital if safety
performance is to be improved. These will include:
2.4.1TheRoleofManagement
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.
2.4.1.1TheMoralImperative
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.
19
2.4.2TheLegalRequirement.
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.
2.4.3TheFinancialorCostBenefitApproach
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.
20
2.4.4TheHumanFactorsApproach
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.
2.4.5TheBehaviouralorCulturalApproach
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.
2.4.6WhatAreManagersRequiredToDo?
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/her
responsibilities 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.
21
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 only
improvement 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.
2.4.7HowshouldManagementfulfilitsResponsibilities?
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.
22
2.4.8TheRoleofEmployees.
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.
2.4.9TheRoleoftheSafetyOrganization
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.
23
2.4.10TheRoleofTradeUnion&EmployeeRepresentatives.
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.
2.4.10.1PositiveContributions.
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.

24
CHAPTERTHREE
METHODOLOGY
3.1Introduction
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.
3.3StudyArea
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.
3.4Targetpopulation
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.
3.5SamplingSize
Random selection of people was done
25
3.6DataCollectionMethodsandTools
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.
3.6.1InterviewMethod
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.
3.6.2Observationmethod
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.
3.6.3DocumentaryAnalysis
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.
3.7DataAnalysisMethod
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.

26

CHAPTERFOUR
DISCUSSIONANDPRESENTATIONOFRESEARCHFINDINGS
4.0INTRODUCTION
This chapter presents the discussion of findings of the study in line with the objectives of the study as
presented in chapter one.
4.1OSHPRACTICESINROOFINGSSTEELROLLINGMILLSFACTORYPHASE3
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;
4.1.1InterviewresponsesandObservedSafetyPractices
CATEGORIES PARTICIPANT RESPONSES
OHS 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 of
Objects
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
27
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
Liquids
Personal 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

Table1: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.
28
Handling/Lifting of Objects
The interview responses in table 1 show that lifting of heavy objects is done by use of machinery like
crane loaders and overhead cranes. This is in line with recommendations of ILO on Iron and Steel
encyclopedia, 2011.
This suggests that workers in Roofings rolling mills do not strain/burden themselves manually with
heavy loads that can affect their health and safety amidst presence of modern materials handling
equipment.

Work environment
The interview responses in table 1 show that there is proper lighting, space between machines,
cooling in sections where heat is generated and cleanliness. This is a safe and health working
environment according to recommendations of ILO, 2005 on Iron and steel safe working conditions.
Safety equipment
The interview responses in table 1 show that there is use of safety equipment for fighting fire,
extraction of fumes and heat. This implies that there are fire safety measures in Roofings rolling
mills.
Sign posts
The interview responses in table 1 show that there are different sign posts and signage used in
Roofings rolling mills. The responses are in line with The Health and Safety Executive (2002), which
demonstrates that warning signs constantly remind workers of the different warning hazards that
include slippery flows, electrical hazards, radiations, heat, noise and no entry to non-staff.
Personal Protective Equipment (PPE)
The interview responses in table 1 show that different types of Personal Protective Equipment (PPE)
is provided to staff for protection against head injuries, noise, fumes, feet and falling while working
at height.
Machines/Equipment
The interview responses in table 1 show that there is use of advanced rolling technology for both cold
and hot rolling operations. Rotating machines are guarded while the section which employs
hydrochloric acid is properly sealed to prevent exposure to workers. This practice is in line with
recommendations by ILO, 2005 that all machines with moving parts should be provided with guards.
Training
The interview responses in table 1 show that there is work place safety training and workers are
properly prepared by supervisors before operation of machines. They also indicate that trainings are
29
rarely done and not based on individual needs. Lydia (2000) noted that health, safety training and
education as a means of communication should be regularly provided to enable the employees and
the workers maintain the basic requirements in occupational health practices. This may suggest why
injuries and accidents do occur. It is advised that safety trainings be given to employees on regular
basis and should be compulsory.

First aid
The interview responses in table 1 show that there are first aid facilities in Roofing rolling mills. The
availability of a clinic with trained medical personnel enables Roofings rolling mills to handle
injuries and sicknesses that arise while at work.
4.1.2Observations
1. Machine operators, maintenance team and supervisors dressing code
The dressing code is a coverall, safety boots, helmet and eye lugs. The dressing code is adhered to as
shown in the photo below;
30

Figure1: Dressing code for operators and production supervisors
2. Availability of safety equipment such as fire extinguishers, fire alarms, fume Extractors
31

Figure2:TheRegenerativethermaloxidizeronColorCoatingLine
3. Condition of Machines
The technology used is the latest and machines with rotating parts are guarded as shown in the fig
below;

Figure3: Machines with rotating parts provided with guards
32
4. Working space
The fig below shows two machines with working space enough for one person and the machine is
also operated by one person by design.

Figure4: Space between two machines, which is normally the working space
5. Condition of working shelter

There is high visibility in different sections of Roofings rolling mills-Namanve. For areas that are
enclosed, there are lights installed as shown below;

33

Figure5: Observation of lighting in a production section
6. Use of safety equipment

Figures below show workers using the different safety equipment while carrying out assigned tasks.

Figure6: A worker using safety harness while at a height
34
7. Sign posts
There are different safety signs at door entries, machines, hot surfaces, where there is a risk of falling
objects, where there is need for given safety equipment, etc. Fig below shows some of the signs in
Roofings rolling mills.

Figure7: Some of the Safety signs at Roofings rolling mills
4.2 MAJOR CAUSES OF ACCIDENTS IN ROOFINGS ROLLING MILLS

This section presents the discussion of findings on major causes of accidents in the factory mills
which includes responses from interviews.
4.2.1Interviewresponses
CATEGORYOF RESPONSE PARTICIPANT RESPONSE
Work Permits Mishandling of work permits
Improper procedure for isolation of machines
before maintenance
The tags used to declare that a machine is under
maintenance are not adequate
There is no training on LOTO for employees
Less follow up work permits
35
Safety culture There is less safety first work culture

There is less safety is every ones responsibility
culture
Personnel practices Negligence on duty
Misuse of machines like grinders
Table2:Observation on Major causes of accidents in Phase 3
Work permit system
From the interview responses shown in Table 2 on work permits, there is a system of work permits
but there is no proper handling of hot work permits, isolating of machines before servicing is not
done in a safe way This is not in line with safety practices in steel industry where Lock Out Tag Out
is designed to direct the servicing of machines and equipments in which the unexpected energizing
or start up, or the release of stored energy could cause stored energy to harm employees performing
maintenance tasks. In the United States, LOTO regulations (29 CFR 1910.47), specifically exempts
so called normal production operations, it focuses on servicing or maintenance operations.
Management should put in place the right work permit system and also train workers on how to
implement it.
Safety culture
According to interview response in table 2 related to Safety culture, worker at the Roofings rolling
mills-Namanve dont exhibit a proper safety culture. This can be improved according to Vecchio-
sadus and Griffths, (2004), who suggested two major strategies used to motivate workers towards
adopting a safety culture and these include promoting management commitment and workers
empowerment.
The interview responses in the table suggest that misuse of PPE is part of the causes of injuries and
accidents in Roofings rolling mills.
Workers should be constantly reminded about proper use of PPE by use of signs and symbols,
constant training and supervision of PPE practices.
Personnel practices
Interview responses in table 2 suggest that personnel practices like misuse of tools and negligence are
part of the causes of accidents in Roofings rolling mills.
These practices and errors can be reduced through developing a proper safety initiatives like safety
first before using any machine or tool.
36
4.3 OSHMEASURESTHATCANBEUSEDTOCURBOCCUPATIONALHAZARDSAT
ROOFINGSROLLINGMILLS
This section presents findings on OSH measures that can be used to curb occupational hazards in
Roofings rolling mills Factory Phase 3-Namanve, which includes responses from interviews.
4.3.1Interviewresponses/Observations
Training Constantly training workers and reminding them
of precautions at the work
Scheduling mandatory OSH workshops for all employees
monthly
PPE Giving the respective PPE to workers when
required using a short procedure
Safety meetings Scheduling monthly EHS meetings to be attended by Safety
officers, managers, production shift leaders and other staff
chosen as representatives of shifts
Making minutes of safety meetings known to all employees by
pinning them on the notice boards

Safety Reporting system EHS department should introduce an incident
reporting system and make it friendly to all levels of work
There should be open safety audits by all
employees to cater for individual safety needs

Table 3: Interview responses/observations on OSH measures that can be used to curb occupational
hazards at Roofings rolling mills-Factory Phase 3-Namanve

From Table 3, training of workers was suggests as a measure to curb Occupational hazards in
Roofings rolling mills. Training of workers is a duty of the employer stipulated by the OSH act of
Uganda (2006) as a means of controlling and eliminating occupational hazards.
Therefore management of Roofings rolling mills-Namanve should continuously assess the need for
training of workers and conduct safety works as a means of developing a safe workplace.
From table 3, PPE is given to workers but there is a long process followed before a worker acquires
the appropriate protective gear. Management should therefore ensure that PPE is easy to acquire
without following a long procedure.
Safety meetings
37
Part of responses in Table 3, suggests that there should be regular safety meeting and minutes
communicated to every worker. Safety meetings should be used to discuss the ongoing safety issues,
review of safety procedures and thereafter come up with better ways to ensuring a safer work place.
Safety reporting system
Part of the responses in table 3; suggests that there should be a proper incident reporting system.
Incident reporting is a common practice in industries where injuries and accidents are studied and
reported with recommendations to avoid re-occurrence in the future. mThe responses also suggest
that safety audits of the plant should be made known to all workers. This helps to increase awareness
and develop a sense of individual commitment to safety practices of workers. Therefore Management
of Roofings rolling mills should develop a friendly incident reporting system and make plant safety
audits known to all workers.
4.4 MAJORCHALLENGESTOTHEESTABLISHMENTOFPROPEROSHSTANDARDSIN
ROOFINGSROLLINGMILLSNAMANVE
This section presents findings on major challenges to the establishment of proper OSH standards in
Roofings rolling mills-Namanve, which includes responses from interviews.
4.4.1Interviewresponses/observations

CATEGORYOF RESPONSE PARTICIPANT RESPONSE
Management Limited manpower to constantly check on OSH standards
in the plant
There is no safety manager to spearhead safety department
Activities
Bureaucracy in obtaining PPEs from safety department
Safety policy
Workers do not have a personal copy of EHS manual used by
Roofings rolling mills for reference
Communication Poor coordination always leads to two superiors giving
different instructions to operators on a production line
Worker awareness

Most employees are not aware of their rights and
responsibilities to safety at the workplace

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

CATEGORY OF RESPONSE PARTICIPANT RESPONSE
Management
Part of the interview responses in Table 4, Indicate that there are management related challenges to
establishment of proper OSH standards which include limited man power to constantly check OSH
standards and the current procedure that applies before a worker acquires PPE. It also indicates that
38
there is no safety manager to head safety related activities and the position has been vacant since
commissioning of the plant.
Management should cover that gap by appointing a safety manager and voluntary safety
representatives from different production shifts and departments. The process of acquiring PPE
should also be reviewed to overcome related challenges.
Safety policy
Part of the interview responses in table 4; indicate that the safety policy of Roofings rolling mills is
not well known to workers of factory Phase 3.. As a result, some safety practices may go unnoticed
by workers. The normal practice Safety in the industry is presenting the policy to workers and issuing
of personal Companys safety manuals for workers reference at all times. Therefore management of
Roofing rolling mills should make all workers aware of its Safety policies through a safety manual
and workshops. On the other hand, IMS has been introduced to other Phases which is the best
practice in OHS.
Communication
From table 4; part of the challenges to establishment of proper OSH standards in Roofings rolling
mills is miscommunication resulting from receiving orders from different superiors. Management
should therefore assign known supervisors to given tasks to overcome the above challenge.
Lack of Awareness
Part of the responses in table 4; indicate that some workers in Roofings rolling mills do not know
their rights to a safe working environment and thus are reluctant to demand for safer working
conditions.
Creating awareness of different worker safety entitlements is the role of the employer and safety
organisation. Therefore Roofing rolling mills should organize workshops to facilitate awareness of
workers rights to a safe work environment.
CHAPTERFIVE
SUMMARY,CONCLUSIONANDRECOMMENDATIONS
5.0 SUMMARYOFMAJORFINDINGS
Findings on OSH practices in Roofings steel rolling mills-Namanve
Findings on the study question revealed that Roofings rolling mills-Namanve has OSH management
system in place, with a safety Department and different safety standards. Findings further reveal that
safety training is not adequate and not mandatory for all employees.
Findings on Major causes of accidents in Factory Phase 3
39
Findings revealed that absence of a proper work permit system, misuse of Personal Protective
Equipment (PPE), lack of a safety culture, personnel practices are the major causes of accidents in
Roofings rolling mills-Factory Phase 3-Namanve.
Findings on OSH measures can be used to curb occupational hazards at Roofings rolling mills-
Namanve
Findings showed that adequate training, easing means of acquiring Personal Protective Equipment
(PPE), making use of regular safety meetings and developing a proper safety reporting system as the
outstanding measures that can be used to curb occupational hazards at Roofings rolling mills-
Namanve.
Findings on major challenges to the establishment of proper OSH standards in Roofings
rolling mills-Namanve
Findings suggested that absence of a safety manager to spearhead occupational safety related
activities, general lack of man power to properly oversee safety practices, lack of awareness of safety
policy of the company among workers, miscommunication from superiors, lack of awareness of
workers about their right to a safe working environment as the major challenges to establishment of
proper OSH standards in Roofings rolling mills-Namanve.
On work permits and LOTO, there needs to be an in depth analysis on the attitude by the middle
line managers, supervisors and the employees themselves. Ignorance about these widely known
safe engineering practices across these levels is worrying and is a time bomb.
5.1CONCLUSION
From this study, it is concluded that Roofings rolling mills has a safety management system in place
and that misuse of Personal Protective Equipment (PPE), absence of a proper work permit system
and personnel practices as the major causes of accidents.
It is further concluded that adequate and compulsory training of workers about proper safety
practices, making use of regular safety meetings and developing a proper safety reporting system to
help study causes and nature of injuries in order to prevent future accidents as the most outstanding
measures to curb occupational hazards at the plant.

40
5.2 RECOMMENDATIONS
From the above findings and conclusions, management of Roofings Rolling Mill should consider the
following;
Ensure that compulsory safety trainings are provided to employees, such that every worker is on board,
with clear understanding of safety requirements, companys safety policy and collective responsibility
towards a safe workplace. Workers should also be given personal copies of the company safety manual.
Ensure that the work permit system functions properly by following up issued work permits by those
who authorize them and enabling workers to acquire knowledge in handling the different types of
work permits.
Speed limit signage ( apprx 10Km/hr) that have been installed along service roads to avoid over
speeding within the plant premises are not complied by most of the drivers.
The use of Personal protective Equipment should be adequate in stores and management should
simplify the procedures followed in acquiring PPE.(Unnecessary signatories should be avoided)
41
5.3SUGGESTIONSFORFURTHERRESEARCH
REFERENCES
1. International Labor Organization, Geneva. (2011).
2. Health and safety problems and patterns. Encyclopedia of Occupational Health and
Safety.Vecchio-sadus and Griffths, (2004). Human safety and risk assessment
3. Worldsteel association (2012). Steel Statistical Yearbook 2012 .Economics committee
Brussels,2012.
4. Tomi J . Lindroos (2009). Sectoral Approaches in the Case of the Iron and Steel Industry.VTT
Working Papers-111, 20.
5. Health and safety executive (2006), Report on the immediate causes of accidents in BritainCullen
MR, Balmes J R, Robins J M, Smith GJ W (1981): Lipoid pneumonia caused by oil
mist exposure from a steel rolling tandem mill. Am J Ind Med 2:5158
6. http://en.wikipedia.org/wiki/Steel, 3rd J an, 2014.
7. International Labour organization, Geneva (2005). Code of practice on safety and health in the
iron and steel industry.
8. The Occupational safety and health act, 2006. Uganda.
9. Constantino, J P, CK Redmond, and A Bearden. 1995. Occupationally related cancer risk
among coke oven workers:
10. Kronenberg, RS, J C Levin, RF Dodson, J GN Garcia, and DE Grifith. 1991. Asbestosrelated
disease in employees of a steel mill and a glass bottle manufacturing plant Ann NY Acad Sci
643:397403
11. Lydahl, E and B Philipson. 1984. Infrared radiation and cataract. 1. Epidemiologic
investigation of iron and steel workers. Acta Ophthalmol 62:961975.
In case of any assistance, supplements and Corrections, Please forwards them to;
Kakama Gilbert
+256774946215
Kgilbert@rrm.co.ug
Kglbrt2@yahoo.com

Occupation Health Safety Practices at Roofing Rolling Mills-Uganda PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Occupation Health Safety Practices at Roofing Rolling Mills-Uganda PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

i

5. Condition of working shelter

6. Use of safety equipment

4.2 MAJOR CAUSES OF ACCIDENTS IN ROOFINGS ROLLING MILLS

Safety culture There is less safety first work culture

Anda mungkin juga menyukai