FACULTY OF CIVIL ENGINEERING AND BUILT ENVIRONMENT

(FKAAB)
SEMESTER 1 2021/2022

GROUP PROJECT: PLANT & MACHINERY INCLUDING

EQUIPMENT TOOLS

LECTURER’S NAME : IR. DR. MOHD NORAZAM BIN YASSIN

COURSE : OCCUPATIONAL SAFETY AND HEALTH (BFC 43502)
SECTION : 2
DATE OF SUBMISSION : 30 DECEMBER 2021

STUDENTS’ NAME:
1. NORANIS FAZILA BINTI MOHD OSMAN DF180171
2. NORASYIKIN BINTI JAAFAR CF190202
3. NUR AFNI BINTI MOHD ALI DF180108

4. NUR ALFAIN AQILA BINTI ABD HAFIZ DF180004

5. NUR AZRINNA BINTI SARI DF180189

MARKS:
 CONTENTS
1. CHAPTER 1: INTRODUCTION .................................................................................................. 1

1.1 Project Background..................................................................................................................... 1

1.2 Problem Statement ...................................................................................................................... 1
1.3 Project Objective......................................................................................................................... 2
1.4 Project Scopes ............................................................................................................................. 2
1.5 Flowchart of Involved Activities.............................................................................................. 2-3

2. CHAPTER 2: METHODOLOGY .................................................................................................4

2.1 Hazard identification, Risk Assesment & Risk Control (HIRARC)..........................................4-5

2.2 Hazard Identification.....................................................................................................................5
2.3 Risk Assessment ...................................................................................................................... 5-6
2.4 Risk Control ................................................................................................................................7

3. CHAPTER 3: DATA ANALYSIS ..................................................................................................8

3.1 Introduction........................................................................................................................... 8-12

4. CHAPTER 4: DISCUSSION ........................................................................................................13

4.1 Introduction.................................................................................................................................13

4.2 Most Critical Safety Hazard................................................................................................ 13-14

4.3 Most Critical Health Hazard ............................................................................................... 15-16

4.4 Control Measure for Critical Hazard .................................................................................. 16-17

5. CHAPTER 5: OVERALL RESULT ..................................................................................... 18-19

6. CHAPTER 6: CONCLUSION

Conclusions...............................................................................................................................20

Recommendations .....................................................................................................................21

REFERENCES ............................................................................................................................... 22-24

 CHAPTER 1

INTRODUCTION

1.1 PROJECT BACKGROUND

Many people are aware that there are numerous jobs in the construction industry such as site clearing,
excavation, concreting, masonry, machine handling, and many more, and each of these jobs has its
own risk of accident occurrence including safety and health hazards, and this report will focus on
safety and health accidents in plant and machinery including equipment tool work. Physical injuries
such as broken arms, dislocations, bruises, and limb loss are commonly caused by safety hazards,
which are commonly caused by poorly maintained machineries and unskilled operators while
operating those machineries and plants. When it comes to health risks, the effects can be long-term,
such as hearing loss due to excessive noise, cancer, dis-coordination, and more.
However, with the right method of control measures in place to reduce the impact of physical
or health effects on workers because of hazards in operating plant and machinery, including equipment
tools on the job site, the probability of injury can be reduced. In this case, an Occupational Safety and
Health Officer (OSH Officer) must observe the entire working environment in order to identify the
hazard and reduce the risk, and a risk assessment will be of great assistance in identifying and
documenting this potential hazard, which was also known as Hazard Identification, Risk Assessment,
and Risk Control (HIRARC). HIRARC assists in identifying all circumstances that may result in
worker danger and facilitating any related parties in planning any preventive measure to reduce the
risk HIRARC will be discussed.

1.2 PROBLEM STATEMENT

As the owner of a construction company that will develop new facilities on the campus of Universiti
Tun Hussein Onn Malaysia (UTHM), such as 20 units of five-story lecture room building, it is critical
for the company to conduct a preliminary risk assessment before beginning the project to reduce the
possibility of hazard occurring on the work site while the project is ongoing. This report discussed and
prepared an appropriate risk control, which can be viewed at the HIRARC table, and further
discussion will be included in this report.

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1.3 PROJECT OBJECTIVES

The purpose of this report is to analyse any potential hazards that have occurred or are likely to occur
during construction site work. The HIRARC table can be used to refer to hazard identification and risk
assessment. After all potential hazards have been identified, this report will assist in determining the
most critical safety and health hazard when handling plant and machinery, including equipment tools,
which will result in physical and mental harm to the affected workers. And from the control measures,
which will also be according to the control hierarchy, including hazard elimination, hazard
substitution, engineering control, administrative control, and finally, Personal Protective Equipment
(PPE).

1.4 PROJECT SCOPES

This project's scope and limitations are solely focused on the plant and machinery, including
equipment tools, at the construction site. The number of hazards that can be identified is limited to ten,
and they must distinguish between safety hazards and at least three health hazards that occur. The
assessment was carried out in accordance with the HIRARC guidelines. The analysis and discussion of
hazards are based on the most important hazard for both types of hazards, which are safety and health.
For the most critical types of hazards, control measures based on the hierarchy of control are also
proposed.

1.5 FLOWCHART OF INVOLVED ACTIVITIES

A lot of stages and works need to be done turn by turn during building construction to ensure that the
building is well constructed, starting with site cleaning, setting out, excavation, piling, reinforcement,
and concreting, all of which require the use of specific tools or machines to complete the work, as
shown in Figure 1.0. Because there will be a lot of machineries that will be used throughout the entire
process of building construction, safety while handling these machineries is critical because a lot of
hazard and risk of hazard will occur during the handling of these machineries.

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 Start

Site Cleaning

Backhoe, Excavator

Setting Out

Graders, Crane

Excavation

Backhoe, Excavator

Piling

Piling Machine

Reinforcement

Cutter, Crane

Concreting

Concrete mixer, Vibrator

End

3
 CHAPTER 2

METHODOLOGY

2.1 HAZARD IDENTIFICATION, RISK ASSESSMENT, AND RISK CONTROL

(HIRARC)

In recent years, the practise of hazard identification, risk assessment, and risk control (HIRARC) has
become a core of risk management in company planning, management, and operations. Organizations
that undertook workplace risk assessments reported a variety of changes in their working practises.
For the results to be credible and the analysis to be thorough, legislation mandates that this procedure
be systematic and recorded. The risk assessment process should not be considered as a one-time event
but rather as a continuous process. Anyone in any economic industry, whether manufacturing,
construction, or any other economic area, can use this HIRARC's technique.

These two flowcharts that can briefly describe the entire process in order to accurately assess
occupational safety at the workplace, as shown in the figures below :

Flow chart of methodology of hazard identification, risk assessment, and control measures

4
 Flow chart HIRARC Process (M.K Shaleh, 2016)

Hazard identification, risk assessment, and risk control are the three main parts, as depicted in
the diagrams above. All of these are required for the HIRARC assessment to be implemented
successfully in the workplace.

2.2 HAZARD IDENTIFICATION

The purpose of hazard identification is to highlight key task operations, tasks that offer major risks to
employees' health and safety, and hazards associated with specific equipment owing to energy sources,
working circumstances, or activities performed. Health hazards, safety hazards, and environmental
hazards are the three sorts of dangers (Department of Occupational Safety and Health, 2008).

This strategy requires us to identify any potential risks that may occur at work based on their
similarity, such as geographical surrounding areas, process phases, activity sizes, and tasks required in
such activities (Department of Occupational Safety and Health, 2008). Hazards can also arise as a
result of various sources, such as machines, equipment, the working environment, or the materials
used.

The information was gathered through observation and interviews with all of the participants.
Examining any hazardous event investigation reports, first aid records, workplace health protection
programmes, inspections, and employee complaints and comments are just a few examples.

2.3 RISK ASSESSMENT

Risk can be presented in a variety of ways to communicate the findings of an analysis so that risk
management decisions can be made. Using a risk matrix to communicate the distribution of risk
throughout a plant and area in the workplace is a very effective technique of presenting the results of a
risk study that employs likelihood and severity in a qualitative fashion. Quantitative analysis uses
numerical numbers drawn from previous accidents, experience, reports, and scientific research,
whereas qualitative analysis uses words to explain the size of prospective dangers (Department of
Occupational Safety and Health, 2008).

5
Risk can be calculated using the following formula:

Relative Risk = Likelihood (L) × Severity (S)

6
 2.4 RISK CONTROL

The goal of risk control is to eliminate, deactivate, or decrease the hazard at its source so that the
worker, equipment, or the environment are not endangered. The application of the most feasible
measure that is reasonable in the context is a successful risk control. To determine the optimal risk
control, review and select short- and long-term measures, and adopt long-term controls only when it is
reasonable. If the danger cannot be reduced, safe work practises have been created by the (Department
of Occupational Safety and Health, 2008). This approach taught workers to work safely in the face of
potential dangers. When it comes to high-risk employment, hazardous work, new duties or equipment,
and intricate chores, it's usually used.

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 CHAPTER 3

DATA ANALYSIS

3.1 INTRODUCTION

The HIRARC assessment from Chapter 2 will be thoroughly analyzed and discussed in this chapter.
The HIRARC table in Table 3.1 tabulates the hazard identification, risk analysis, and risk control of
the activity focusing on the mechanical plant and machinery of the construction. The work activity at
the construction site is identified as part of the assessment. To propose the consequences obtained
from the hazard, the hazard for each activity and the existing control are recognized. Then, in the
column supplied, the rate of likelihood and severity of each hazard encountered throughout the
construction process is tallied to determine the critical risk level.

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 TABLE 3.1 : HIRARC TABLE

1. Hazard Identification 2. Risk Analysis 3. Risk Control

PIC
Recommended (Due
Existing Risk
Which can Likelihoo Control date/
No. Work Activity Hazard Control (if any) Severity Risk
cause/effect d Measures status)

Engineering
Operating Fatigue, Irritability,
Whole body 9 controls,
1. excavating and Headache, Disorders - 3 3
vibration (Medium) Separation, Job
piling equipment of the spine
rotation

9
 Use low possible
vibration tools,
tools should be
Hand arm vibration properly
Using pneumatic
Constant hand- syndrome (HAVS), 9 maintained so that
2. drill and vibrating - 3 3
arm vibration tingling, numbness (Medium) they are balanced
machine
and blanching of and have no loose
fingers parts, wearing anti-
vibration gloves.

Install an
emergency stop
cables. Allow only
trained and
Using cranes to competent person
unload steel Crushed/ to operate the
Fatal, broken of body 15
3. structure/ Struck by - 3 5 plant. Do regular
parts (High)
materials like heavy loads inspection and
piling maintenance of all
mechanical plant
and machinery
system also
supervision during
work
Substitute with
4. Using cabled Tangled cable Slips, trips and falls - 3 4 12 wireless tools,
vibrator or hose e.g. oil leaks (Medium) housekeeping
connection

Using electric Serious cuts, hand get

Cutting,
saw, contact with caught from the 9 Moving part
5. unguarded PPE 3 3
rotating cutting rotating part of (Medium) should be enclosed
machine,
disc machine and guarded,

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 unsafe work conduct Tool Box
practice Talk on safe
operation of
machinery, install
signage about the
hazard, work
carried out by
training personnel

Operating the
machine and Heat rashes, Providing shelter
mechanical plant heat stroke, Faint, dizzy, nausea for rest, operating
8
6. during hot day and heat or vomiting, may lost - 4 2 the mechanical
(Medium)
exposed to exhaustion or consciousness plant during cooler
excessive/direct heat cramps day
sunlight
Providing personal
protection
Long term hearing 9
7. Piling and Loud noise PPE 3 3 equipment such as
loss (Medium)
excavating work hearing protector

Provide
supervision,
Crushed by
Reassembling of Can cause fatal to the 12 providing PPE
8. components in - 3 4
piling machine workers (Medium) such as safety
piling machine
helmet and safety
vest
Driving Providing
Collision
machineries, such systematic routes
between Minor scratches,
as forklift, crane, Competent 12 for heavy
9. vehicles and permanent injuries, or 3 4
and excavator, operator (Medium) machineries, create
may involve death
around the partitions between
other workers
workplace pedestrian

11
 wakways and
roads

10. Using sawing Inhaling wood /silica - 5 3 15 (High) Providing PPE

Inhaling of dust that leads to
machine, such as such as face mask,
wood dust cancer, sinuses and
circular saw and suitable ventilation
and inhaling lung disease
woodcutting to eliminate wood
of the silica
machine, brick dust and water
dust
and concrete suppression to
cutting, blowing reduce the dust
concrete dust level
with compressed
air

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 CHAPTER 4

DISCUSSION

4.1 INTRODUCTION

This chapter will be discussed on the most critical safety hazard and and the most critical health
hazard. This chapter will also focusing on ways to control measure for critical hazard.

4.2 MOST CRITICAL SAFETY HAZARD

Crushed or struck-by-heavy-loads is the most serious safety hazard identified at this construction site.
This hazard has a rate of 15, indicating that the danger is high. According to HIRARC principles, each
high risk situation requires urgent control using the hierarchy of control (Department of Occupational
Safety and Health, 2008). An impact or violent contact between an object or equipment and a person is
defined as crushed or hit (OSHA Directorate of Training and Education, 2011). Heavy machinery,
such as vehicles, falling objects or materials, and masonry walls or concrete being constructed are
three categories that employees are frequently crushed or damaged by (OSHA Directorate of Training
and Education, 2011). During the inspection, this hazard can occur due to the use of a crane to unload
construction materials such as steel structures such as shown in Figure 4. The condition of the
machinery, how they are operated, and the person operating the crane are all contributing factors to
this hazard. Cranes that are not properly managed, as well as those that are in poor condition, might
create accidents when unloading materials. The usage of cranes that do not fulfil requirements, as well
as overloading over the crane's permitted capacity, can cause the crane to fail to work effectively, will
be resulting in potentially fatal accidents. It's also conceivable for the crane to collapse and cause
havoc on the construction site. The individual in charge of the machines is likewise incompetent and
has not received sufficient training, increasing the potential of a danger.

13
 Figure 4: Unloading construction materials that can cause hazard (OSHA Directorate of
Training and Education, 2011)

The impact of safety on workers can result in shattered body parts and, in the worst-case scenario,
death. This assertion is backed up by the US Occupational Safety and Health Administration's
(OSHA) Focus Four Hazard, which indicates that the hazards are among the most common causes of
death and non-fatal injury (OSHA Directorate of Training and Education, 2011). Non-fatal injuries to
workers include both permanent and non-permanent disabilities. Broken bodily parts, such as legs and
arms, are examples of permanent and non-permanent disabilities that can occur. Internal injuries, on
the other hand, are the ones that result in death. Workers working beneath the load are at a great
danger of being crushed by the suspended load. It might be worst when the crane exceeds the load
capacity and causing malfunction and harm to the workers and including the heavy machinery itself.
The severity and likelihood are rated as 5 and 3 respectively. The likelihood is conceivable which
shows it might occur sometimes in the future but the effect is worst which the severity of the hazard is
considered catastrophic (Department of Occupational Safety and Health, 2008). This is due to if the
load falls or the machine is overturning, the nearby workers that work near the site can experience the
risk of fatalities on the spot. The machinery will face damage and bring losses. Productivity is another
expectation that includes catastrophic severity due to the ongoing construction is also at risk of being
affected as well.

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4.3 MOST CRITICAL HEALTH HAZARD

Inhaling wood dust and silica dust are the most serious health threats in the HIRARC table, with a risk
rate of 15 and a high classification. Heat stroke, long-term hearing loss, hand-arm, and body vibration
are some of the other health concerns that workers face, but they do not result in death. The critical
health danger identified is similar to that stated in the literature review, indicating that the death rate
from silica dust exposure is significant. Dust is a non-mechanical danger associated with construction
machinery that can be hazardous to workers and can be serious if not properly controlled (Workplace
Health and Safety Queensland, 2019). This hazard is obtained from a few activities, namely the use of
sawing machines such as a circular saw and woodcutting machine. The production of silica dust
arising from activities such as concrete cutting and blowing concrete dust with compressed air such as
shown in Figure 5. According to ( Government of Western Australia, 2015), wood can be divided into
three main categories, which are hardwoods such as oak, jarrah, and teak, softwoods such as cedar and
pine, and lastly man-made woods. Man-made wood is an engineered wood product such as medium
density fibreboard (MDF), laminated veneered lumber (LVL), and particle board or can be known as
chipboard. Meanwhile, for silica dust, the dust is produced from working from silicacontaining
materials. Concrete, sandstone, and mortar are examples of materials that contain silica (HSE, 2013).

Figure 5: Example of cutting activity that produces dust (Health and safety Executive
(HSE), 2013)

15
 The severity level of this hazard is at 3, indicating that it is serious and may result in non-fatal
harm but lifelong disability (Department of Occupational Safety and Health, 2008). There are no
fatalities listed under this intensity, but the long-term consequence causes cancer, which can develop
and cause death within a short period of time. This effect takes time to develop and cannot be noticed
immediately, but by the time it is recognized on an individual, it may be life-changing and serious
(Health and Safety Executive (HSE), 2013). Meanwhile, the hazard's likelihood rating is 5, indicating
that the danger is most likely to occur as a result of no existing control at the building site. When
workers use machine equipment at a high rate, they are exposed to a lot of dust.
Inhaling wood dust can cause respiratory difficulties such as sinusitis, and in the worst-case
scenario, it can lead to cancer and lung illness in the long run. The International Agency for Research
on Cancer (IARC) has classified wood dust as a human carcinogen (Government of Western Australia,
2015). Fine wood dust produced by beech and oak is breathed and causes cancer. Other tree species,
such as birch, mahogany, and teak, have been linked to cancer (Government of Western Australia,
2015). The NSW Government also supports another consequence that leads to sinuses, stating that
contact to wood dust can cause nasal irritation and violent sneezing. Rhinitis (runny nose), nose
bleeds, and clogged nose are all symptoms of rhinitis (NSW Government, 2017). Silica also creates
the same effect as wood dust as the particles can cause silicosis due to the dust travel deep into the
lungs (Occupational Safety and Health Administration (OSHA), 2017) the worst effect of inhaling
silica can lead to deadly lung disease and lung cancer.

4.4 CONTROL MEASURE FOR CRITICAL HAZARDS

The usage of mechanical and powered tools is common in construction activities. By referring to the
HIRARC form, the most critical health hazard could be occurring is the excessive inhalation of
particles into the worker’s body specifically wood and silica dust during the activity of wood, brick
cutting and 21 concrete dust blowing. Rated with a high level of risk, this hazard must be controlled as
the long-term effect might lead to a chronic disease among the exposed workers such as lung cancer,
dermatitis, skin irritation and more. The hazard can be prevented and controlled by following the
hierarchy of control including elimination, substitution, engineering control, administrative control
and personal protective equipment (PPE) as shown in Figure 6 (The National Institute For
Occupational Safety and Health, 2015). As can be referred from the figure, the most effective
prevention of hazard would be elimination of hazard and risk followed with the least effective method
which is the application of Personal Protective Equipment (PPE) on the workers

16
Figure 6: Hierarchy of Control (The National Institute For Occupational Safety and Health,
2015)

17
 CHAPTER 5

OVERALL RESULT

Based on the analysis of this study, HIRARC Process is consider very important as the outline
provided the right path in determination of the flow for risk management at work place. Besides this
process are outline into three different level which are Hazard identification which is to determine and
classify the type of work that can cause harmful incidents towards the community that work at the
plant and machinery including equipment tools department. Next, the HIRARC Process second step is
risk assessment. This part is considered very crucial as this will be needed estimation part in order to
make sure that the risk was assessed correctly according to Department of Occupational Safety and
Health (DOSH) rules and regulation. The calculation of risk also included as this part will becoming
the biggest outcomes for the next step which is risk control. Risk control can be considered the phase
before achieving the completion of HIRARC process. Therefore, in this phase, all of suspected hazard
that needed attention will be needed plan for reducing the risk percentages and also planning for
prevention.

Besides HIRARC process, references from methodology also vital. This is because in the
terms of hazard identification, risk assessment and risk control, which are consider most important part
in the risk management. The flow chart at 3.1 which shown that the first step is the classification of
work activities area wise. The last step of this flow chart of methodology is monitoring which will
need review from safety committee that will provides two representatives which are employee and
worker to go through every single step after the classification of work activities and wise again. The
main reason of this activity is to give reassurance.

The HIRA is not meant to be a scientific evaluation of the frequency of various hazards;
rather, it is a risk assessment that must examine the likelihood that a hazard would occur with
sufficient force to cause an emergency scenario. Some dangers lack a long track record, and their
frequency can only be calculated using the best available data. In an ideal world, the frequency would
be determined by the number of times the event has occurred rather than by the number of years.
Impact Hazards can have a wide range of consequences. This research's findings were gathered and
examined. Past consequences and present mitigating strategies were examined to see if similar
damages may be predicted in the future if similar events occurred.

Construction operators will be able to determine high, medium, and low risk levels using risk
assessments. Understanding the hazard, combining evaluations of probability and severity to provide
an assessment of risk, and it is used in the assessment of risk as an aid to decision making will assist to

18
prioritise risks and offer information on the possibility of harm emerging and degree of harm.
Machinery owners and operators will be able to adopt safety enhancements in this manner. To make
the mining workplace better and safer, many sorts of techniques for mine safety, varied tools, and
suitable procedures must be implemented.

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 CHAPTER 6

CONCLUSION

In the nutshells, the hazard in the workplace can be identify by collecting the data, analyze and
classify the contribution factors that causes of the accident or incident. There are three basic accident
causes commonly occur in the workplace which are unsafe act, unsafe condition and unplanned
incidence. For unsafe acts and condition can be categorized as human behavior, the design of
machinery and plant, the systems and procedure while using the material and substance and the
environment surroundings. Then, take an action that help to formulate the recommendations and
determine the control measures (Office of Risk Management, 2019). Therefore, an accident
investigation is needed in order to get the roof of causes to prevent anything could be happen in the
workplace.
An incident investigation is a management tool by which work related injuries, ill health,
diseases and incidents are systematically studies for the root causes and contributing factors to be
identified. This is benefit for Occupational Safety and Health Organization’s management system to be
continually improved. Generally, incident investigating is important to prevent repetition of the same
work-related injuries, ill health, diseases and incidents. Besides that, by following the steps in incident
investigation is crucial not only to minimize injury and loss but also to protect evidence necessary to
conduct the investigation (Office of Risk Management, 2019). Then, this is also to get an accurate
record such as for insurance, legal prosecution, public enquiries as well as legal requirement and for
policy and business reasons of an organization. Moreover, according to procedure principle of
investigation are needed to carry out all incident information and must handed by competent persons
with participation of workers. As the result, external investigation reports such as DOSH and SOCSO
must be included in management review (NIOSH,2005)

Lastly, every accident happened were an unplanned, unexpected and uncontrollable

occurrence thatinvolving injury in short term and long term or death to the workers and also damage
to the machinery plant. These accidents should be concerned about and take an action to prevent the
repeated incidents or accidents. To be highlighted, these is need to avoid from happening and must
to find the way to minimize the rate of accident by providing a safe working condition and enhance
the methods and procedure improvement as the control measure action in the future. Every
organization that involves in Occupational Safety and Health must to take the responsibilities in every
action and decision does make in order to reduce the number of accidents occurring at the workplace
that is keep increasing every year due to the unpredictable reported especially in Malaysia
(UKEssays, 2018).

20
 RECOMMENDATIONS

Furthermore, the health and safety hazard are important that need to be consider in the workplace
by employers and employees. Generally, safety hazard is a situation with risk that must to deal
while health hazard is a risk left that affect to people’s life. By identifying health and safety
problem can be easy with analyze the root causes and following the caution in the workplace.
Hence, both men and women could be affected by reproductive hazards at work. Recently, there are
many concerns and awareness improvement regarding to the health and safety of the workers in
industrial, manufacturing and construction organization. These organization should provide the
workers with the best condition and not exposed to health and safety risk during work especially for
the critical activities such as handling the mechanical plant, working from the height place and work
with exposure hazardous substance and materials.

As employer, briefing about health and safety hazards is the most important and the first
thing that must to do before starting the work. Besides that, do regular inspection and maintenance
of all mechanical plant and machinery system as well as supervision the workers during work. They
need to allow only trained and competent person to operate the plant and system. In other hands, as
employees need to wear a complete set of Personal Protective Equipment (PPE) that provided by
employers. For example, use the suitable face mask to eliminate wood dust from entering to human’s
body and water suppression to reduce the dust level. Meeting project is also important not only can
get in touch between employees and employers but also they can discussed the cases and issues that
happened during the project held. So, the data regarding to the safety and health can be collecting
easily to analyze more detail about the root causes of events for the further planning. This is maybe
makes impossible to act in a proactive manner to decrease health risks although this is very much
possible if the risk involved is a safety risk.

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