Construction site incidents for lesson learning

Construction site incident

Construction site incident CASE – 1

Brief Description:

A crew of 3 persons was probably actively involved in shifting the Crawler crane from the site and they were below the mast at the time of movement of the crane. During this process mast of the crane fell suddenly causing injury to them.

Immediately all three injured persons were rescued by the Contractor site personnel and were shifted to hospital for medical treatment. However, the doctor declared one worker dead and the other two workers were discharged from the hospital after medical treatment.

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Probable Cause of incident:

  • The incorrect angle between mast & gantry while restoring mast to storing position.
  • Sudden slackness in ropes due to bending of the mast causing the mast to fall down.
  • While guiding signaling to the operator/ clearing path at the time of movement of the crane, victims came below the crane mast & mast fallen down suddenly.

Lesson Learnt/ Recommendations:

  • Competency of a crane operator to be thoroughly checked prior to engaging in crane operation.
  • Lifting/ loading/ unloading activities shall be carried out by the trained riggers only under the supervision of rigging Foreman.
  • Prior to the marching of the crane, obstruction-free access to be ensured.
  • Logbook of the all Crane to be maintained religiously. Checking of the crane to be done by the experienced supervisor prior to putting in operation.
  • The mast of the crane to be kept in the right position during the dismantling activity of the crane.
  • The healthiness of the Crane to be checked by Crane expert on a regular basis as per manufacturer guidelines & record of the same to be maintained.

Construction site incident CASE – 2

Brief Description:

A Rigger & Crew of six members were involved in the erection of pipe spool of dia.24 ” & 11 mtrs length (weight 7T). A 150T Crawler crane, two Web Slings, and two Chain Pulley Blocks were used for the erection. Erection was carried out at 10mtr. elevation in the Pipe rack area.

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During the course of erection, due to the wrong assessment & imbalance of pipe, the spool inadvertently swung towards the other end and hit the scaffold plank wherein Rigger was moving on the platform. Resulting in, he got trapped in between the pipe spool & scaffold platform & was severely injured on his thighs. The victim was immediately rescued & shifted to hospital for treatment. However, he succumbed to his injuries the next day.

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Probable Cause of incident:

  • Failed to secure Pipe spool by providing adequate chain pulley blocks to restrict the unintentional movement of the load.
  • Lack of understanding about the job-specific hazard & their consequences.
  • Hurry to complete the job.

Lesson Learnt/ Recommendations:

  • A chain pulley block with adequate capacity should be provided on the pipe to secure the spool & restrict the unintentional movement of the load.
  • Erection activity shall be carried out under the supervision of an experienced Supervisor/ Engineer.
  • Erection activity shall be carried out as per the approved Job procedure/ method statement.
  • Ensure no work is carried out hurriedly.
  • Job-specific HIRAC to be ensured for critical activity.

Construction site incident CASE – 3

Brief Description:

Two workers were performing the grinding activity by positioning themselves on a man basket, which was lifted to a height of 15mtr by an electrical hoist. During this process, the chain-link of the electrical hoist failed (got cut) leading to the free fall of the man basket. As the workmen have anchored their full-body harness to their individual grab arrestors to vertical lifelines, both the workers were hung on their lifeline and were rescued immediately. The workers sustained a minor injury.

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Probable Cause of incident:

Failure of chain link of electrical hoist.

Lesson Learnt/ Recommendations:

Inspection of a chain link of electrical hoist & related internal parts to be done by an experienced person prior to use the same.

Construction site incident CASE – 4

Brief Description:

The Welder & helper was engaged for welding of electrical cable tray support at 14mtr. elevated location. The helper was slipped and fell down while he was going to fetch the welding electrode. During movement at height Helper was not anchoring the lanyards of full-body safety harness. Safe access was not arranged at the workplace.

Probable Cause of incident:

  • A lanyard of full-body safety harness was not tied by suitable means by the helper during movement at height.
  • Missing of safe access for movement.

Lesson Learnt/ Recommendations:

  • The lifeline shall be installed for anchoring of lanyards of full-body safety harness.
  • Safe access to be provided for height jobs.
  • 100 % tie-off policy shall strictly adhere at the workplace.

Construction site incident CASE – 5

Brief Description:

Two Rigger & one Helper was assigned for shifting of the pipe spool at an elevated location. Shifting of Spool was carried out using two chain pulley blocks & two web belt slings. During shifting of the spool, it lowered at little and stuck with Structural Beam, one Rigger walked to the end of the spool to raise it.

As Rigger tried to raise the spool stuck portion, the chain pulley block got failed & the spool dropped down. The rear portion of the pipe spool hit on the right leg of a Rigger & he fell down Immediately injured person was rescued by co-workers & shifted to hospital for medical treatment.

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Probable Cause of incident:

  • Failure of chain pulley block.

Lesson Learnt/ Recommendations:

  • The higher capacity of chain pulley in good condition to be used at the workplace.
  • All lifting tools and tackles to be checked on a regular basis prior to use.
  • Strict supervision to be ensured at the workplace.

Construction site incident CASE – 6

Brief Description:

Two Riggers & two helpers were engaged for shifting and positioning of 16 ” dia. Pipe with three chain pulley blocks & three web slings belt. Initially, all four workmen were operating the chain pulley blocks to positioning the pipe.

Suddenly one chain pulley block got stuck inside the chain pulley. In order to make the chain free, one worker moved toward the chain pulley block. As soon as he released the trapped chain, the 16 ” dia pipe moved with sudden thrust & hit the adjacent pipe which causes rolling of pipe and hit to worker’s right lower leg. Immediately the injured person was brought down by man basket & shifted to hospital for treatment.

Probable Cause of incident:

  • Temporary locking was not provided to the adjacent pipe.
  • Inadequate supervision.
  • Nondeployment of skilled manpower.

Lesson Learnt/ Recommendations:

  • Ensure locking arrangement after the erection of the pipes.
  • Skilled manpower to be deployed & adequate supervision should in place.
  • Good quality of chain pulley blocks to be ensured for erection/ li┼┐ting/ shifting.

Construction site incident CASE – 7

Brief Description:

During slab de-shuttering and scaffolding activity at Substation building a 6-meter scaffolding pipe, weighing approximately 15 kg free fell from a height of 13 meters, landed on the dividing road between an existing unit & under construction Substation building periphery. No injury noticed.

Probable Cause of incident:

  • During slab de-shuttering and scaffolding dismantling activity, no checks were carried out to ensure that there was no loose material kept at height.
  • De-shuttering activity one pipe removed and kept in between the scaffolding materials.
  • The pipe which was kept with the scaffolding materials rolled out and fell from a height and landed vertically on the ground.
  • No fall protection to arrest falling objects.

Lesson Learnt/ Recommendations:

  • Supervisors must to ensure that no loose materials are to be kept at the edges in loose position.
  • Ensure fall protection systems like catch nets to be provided to protect from accidental falls.
  • Permit to work & job safety analysis must be specific and capture all inherent risks associated with the task.

Construction site incident CASE – 8

Brief Description:

While carrying out hot work at an elevation of 5mtr due to improper spark confinement a splatter fell on the open drain just below the hot work area resulted in the minor fire occurred due to the presence of hydrocarbon. No human injury.

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Probable Cause of incident:

  • Fire Booth was not properly made.
  • Below drain was not properly covered.

Lesson Learnt/ Recommendations:

  • All hot works to be done only after ensuring proper confinement of fire blankets.
  • All drains below hot work shall be covered using metal sheet/ fire blankets. Availability of fire hose, fire extinguisher, and a fire watcher shall be ensured before the start of the activity.

Construction site incident CASE – 9

Brief Description:

250T Crane (Kobelco) was swinging in the project area for works, in the meantime, the main hook of the crane touched the luffing jib pendant rope of another crane (SANY 80T) and hook got stuck in the pendant rope (arrested by hook latch). No injury or property damaged.

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Probable Cause of incident:

  • Lack of Supervision.
  • Poor coordination between crane operator and signal man.

Lesson learnt/ Recommendations:

  • Two cranes should not swing Simultaneously in the same direction The lifting hook of the crane should be as high as possible while swinging.
  • Ensure the position of the lifting hook before the end of the day.

Construction site incident CASE – 10

Brief Description:

Trail Pit Excavation of OWS (Oily water sewer) in front of the transfer area of the substation was under progress using JCB. During excavation, the JCB bucket came in contact with underground high voltage electrical cables and damaged the live cable. It resulted in the tripping of the electrical panel in the Substation. No human injury.

Probable Cause of incident:

  • No work permit was taken for excavation.
  • Trail pit excavation was carried out by JCB.

Lesson Learnt/ Recommendations:

  • Manual excavation shall be done for the trial pit.
  • A work permit to be ensured prior to start activity.
  • The activity shall be performed after implementing the mitigation measures as per HIRAC.
  • Adhering to specific testing/ inspection of underground cable prior to start the job, if any.

Construction site incident CASE – 11

Brief Description:

During Box up, activities of MCC, rear door of Condenser toppled from three mtr. height during fixing flange joint at working platform due to failure of weld joint of sliding link holding the door with the davit. Due to a fall impact, the grating on the working floor got damaged along with one supporting structural member below the working platform. No human injury.

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Probable Cause of incident:

Failure of weld joint of sliding link holding the door with the davit.

Lesson Learnt/ Recommendations:

Prior to installation of equipment, it should be checked thoroughly by execution/ quality team.

Construction site incident CASE – 12

Brief Description:

The injured person was inspecting the Column internally by holding a lamp in his hand & moving downward along with the lamp. Simultaneously inspection was carried out by other teams at different elevations (above the victim inside the column).

To facilitate inspection, the ladder was repositioned by workers & metal clamp brought inside the column for firm fixing the ladder. The clamp kept on the tray. During downward movement, metal clamp fell on the victim helmet from 10mtr height resulted in braking of safety helmet and caused slight cut injury on his head. Immediately victim was shifted to hospital for medical treatment.

Probable Cause of incident:

  • Loose materials was kept at elevated location.

Lesson Learnt/ Recommendations:

  • Loose materials to be removed from an elevated location or secured firmly by suitable means.
  • Workers/ staff shall be attentive at the workplace.
  • Simultaneous work at an elevated location to be avoided.

Construction site incident CASE – 13

Brief Description:

A Rigger was returning to the site with two-liter Water bottles accidentally his leg got entangled with electrical cables, resulted in he fell down on the ground level and sustained fracture injury on his right knee cap. Immediately victim shifted to the hospital for medical treatment.

Probable Cause of incident:

  • Failure of Proper electrical cable management.

Lesson Learnt/ Recommendations:

  • Welding & electrical to be routed in safe manner so that it should not obstruct the access.
  • Safe access to be ensured at workplace for movement of site personnel.
  • Arranged awareness program for Trip and Fall Hazards.

Construction site incident CASE- 14

Brief Description:

While performing the preparatory work for lifting of feed surge drum with using two crawler cranes, capacity of 350MT and 150MT, the orientation of equipment and the position of saddles had to be changed before lifting for erection. For shifting the saddle, the equipment was lifted from tailing end by using 150 MT crane.

The Group of two workers was engaged on both sides of the saddle to lift & shift it by using a scaffolding pipe. IP was shifting the packing (wooden block) which was provided under the saddle, due to area congestion manually handled the task. While pushing saddle, it got unbalanced and fell down. The saddle stuck on IP’s back while he was trying to escape from the location. IP sustained a minor injury on his right side lumber region.

Probable Cause of incident:

  • HIRAC for non-routine/ unplanned sub-activities i.e. changing the orientation of the equipment & shifting of the saddle was not carried out by the crew.
  • Poor coordination between the two crew who were engaged in lifting & shifting of the saddle.
  • Space constraints-The saddle should have been shifted by mechanical aid but due to space constraints, shifted manually.

Lesson Learnt/ Recommendations:

  • Hazard associated with non-routine/ unplanned activity shall be identified and risk assessment shall be conducted before the start of the activity to identify and manage any change.
  • Hazard associated with the activity and safety measures to be adopted during activity shall be communicated to the working crew.
  • Mechanical aid shall be used for shifting the heavy object like equipment saddle.
  • The supervisor shall ensure that crew is not in the line of fire.
  • Proper communication between the crew members shall be ensured during lifting activities.

Construction site incident CASE- 15

Brief Description:

The victim went to take PP Rope which was kept on 210 elevations of refrigeration package platform for lowering of dismantled scaffolding materials. During the course of action, he was walking on the grating floor. Suddenly, one of the grating was displaced from its position, resulted in worker felt through the opening from 2nd elevation to 1st elevation & sustained injury in the right leg.

Probable Cause of incident:

Grating was not firmly fixed on 2nd elevation platform

Lesson Learnt/ Recommendations:

  • All grating shall be checked before deploying workers at the elevated platform.
  • Awareness to be created to all workmen by training & Tool Box Talk.

Please share your company incident with me on rlshumancare@gmail.com, RLS HUMAN CARE does not disclose your company name.

RLS HUMAN CARE request to you please share this incident with your friends and working professionals to avoid this type of incident in the future.

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Saurabh Ranjan is Founder of rlshumancare.com. I have dedicated & committed to publishing some innovative content and useful topics regarding Health, Safety & Environment, which will help and awareness to people for daily life. Also trying to continually improve my content for better awareness and suit to dedicated people.

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