GC3 Report (Raja Aammad)

GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number of _____
Student name:______ Raja Aammad Masood Satti_________ Student number: ____00382919______
Place inspected:_________ BESTWAY CEMENT HATTAR___ Date of inspection: 29/04/2017
Observations Control measures Timescale

Hazards and consequences Immediate and longer term actions
1) Rotary Drill was placed very close to Move drill away from quarry face. Immediately
the quarry face on an even ground Conduct Training regarding safe 6 Days.
during drilling operations in quarry usage of Rotary drill for all drill
presenting a hazard of fall from height operators.
of drill endangering life of driver and Develop Inspection routine for 1 Month.
the workers working beneath the quarry. inspection of ground conditions
before placing drill.
Develop safe system of work. 2 Months.
2) Warning signs were not used to alert
people of explosives used in blasting Stop the explosive work. Immediately
limestone rocks, Explosives used can Use warning Sirens to alert people 5 Days
cause serious injuries, broken bones and before explosion.
even death if people come across
Arrange and install warning signs 2 Months
unaware of blasting due to
at suitable places.
unavailability of signs.
3) Dumpers were carrying the heavy

rocks to Hammer crushing unit. Tyres
Report to Supervisor. Immediately
of one of the dumpers were in worn out
condition which can cause overturn, Stop use of Highlighted Dumper. Immediately
slip or collision incidents due to poor Replace Tyres. 6 Days
road grip. Develop Inspection routine. 1 Month
4) Heavy Machinery and Vehicles used

in quarrying, crushing and Production Rest Breaks 2 Hours.
process were making excessively loud Provide Ear Defenders or ear plugs 1 Day.
noise which may result in hearing as necessary.
problems like tinnitus, temporary Job Rotations. 1 Month
ringing in ear, temporary hearing loss or Health Surveillance of workers. 2 Months
even NIHL if OEL of noise is exceeded. Maintenance of Vehicles,
Equipment and Machinery. 3 Months
/conversion/tmp/scratch/374038405.doc
5) Workers were working very close to
the unprotected edge in quarrying area Dont work near Edges. Immediately
without any supervision which may Work under supervision. 5 Days
result in fall from height and can cause Install appropriate Edge 2 Months
Vertebrae Column injuries, fractured Protection.
bones and even death of workers.
6) Dust hazard was present throughout

the process because of presence of dust Provide respirators to workers as 1 Day
size particles of silica, clay and laterite required.
etc. It can lead to eye, nose and throat Job Rotation. 1 Month
infections and can also cause serious Rest breaks. 2 Hours
Respiratory track problems like asthma,
Provide adequate Dilute 2 Months.
silicosis and lung cancer.
Ventilation.
Health Surveillance. 2 Months.
7) Fall of small sized rocks from
overhead conveyer belts. People were
moving beneath the conveyer belt Barricade the area beneath 3 Hours.
without head protection and no overhead conveyers.
appropriate side guards were present on Provide suitable hard hats. 2 Days.
conveyers which can lead to severe Routine Visual Inspection. 1 Week
head injury and even death. Install machine guards. 1 Month
8) Raw material is moved from raw

mill in to the Rotary Kiln where
Clinker is produced at high Provision of isotonic drinks Immediate.
temperature of about 2000C. Extreme Rest breaks 2 hours.
temperature conditions were observed Suitable Clothing 1 Day
with workers not wearing adequate Job Rotation 3 Weeks.
clothing and PPEs and there were no Availability of Cool refuges 3 Months.
refuge areas that may result in
dehydration, muscle cramps and heat
stress.
9) Door of Emergency Escape route

from raw mill was jammed due to
presence of excessive amount of dust
at the bottom of door which is a Remove the dust. Immediately.
serious hazard, it can increase the Level the base of door. 1 Day.
gravity of incident should any Routine Visual Inspection. Every week.
unwanted event occurs and may lead to
serious injuries and death of people
inside raw mill.
10) Machine guards were not used in

packaging machine of cement Keep Safe distance. Immediate.
presenting mechanical hazards like
Rest Breaks. 2 Hours.
cutting, entanglement, friction etc.
Provide appropriate hand 1 Day.
Workers hands and arms can easily
protection.
entrap in moving parts of packaging
machine causing severe injuries. Work under Supervision. 6 Days.
Install fixed machine guards. 1 Month.
11) High voltage Electric Panels in
packaging area were not covered and Cover Electric Panels. Immediately.
locked properly and no warning signs Apply LOTO. 1 Day.
were displayed, presenting electric Not allow unauthorized access. 4 Days.
hazards like shock and electric burns to Routine Visual Inspection. 2 weeks.
people in the vicinity and also could Training on hazards of Electricity. 1 Month.
cause fire and explosion.
12) Designated Parking areas were

present and all vehicles were parked at
their designated spots. Parking Should be continued. Continue.
assistant was also there to assist drivers
in parking safely without posing
hazard to other vehicles and
pedestrians.
13) Coal used to run Rotary kiln and

Provision of suitable Respirators to 1 Day.
chemical processes involved in
workers in the area.
production of lime pollutes
Job Rotation to workers working 2 Weeks.
environment by producing large
in Kiln.
quantity of Carbon dioxide (CO2) gas
resulting in ill health of workers and Providing Fresh air refuges to
the people in surroundings. workers. 1 Month.
Enhancing energy efficiency of
Rotary Kiln. 3 Months.
Using alternative fuels sources like
natural gas can reduce emission of 3 Months.
CO2.
14) Excessive Vibration was produced
during Rotary drill and crushing Keeping safe distance from Immediately.
operations of heavy rocks which can Source of vibration.
lead to joint damage, Spinal disc Job rotation. 2 Weeks.
damage, blanching etc., if OEL of Routine Maintenance of Machine. 3 Months.
vibration is increased. Health Surveillance of workers. 2 Months.
15) Adequate Light levels were

maintained at almost all working areas
providing good visibility to workers Good practice and should be Continue.
avoiding risk of incidents due to poor continued.
lighting conditions.
16) Forklift truck in the packaging

area was reversing without audible Dont reverse the truck.
reversing alarms and flash beacons to Install flash beacons and audible Immediately.
warn the pedestrians, there was no reversing alarms to truck. 6 Days.
banks man either to guide the driver. Hiring a banks man to guide driver
This careless practice can lead to while reversing. 1 Month.
collision with fixed objects and Arrange Defensive driving training
pedestrian working in the vicinity. for all drivers. 2 Months.
17) Edge of one of the stairs in clinker
cooling area was damaged presenting Avoid using stairs if possible. Immediate.
hazard of trip and fall which may Put warning sign to let people 3 Days.
cause fractured bones, head injury and know of damaged stair.
even death in worst case. Repair the stair. 1 Week.
Periodic Visual inspection of 1 Month.
workplace.
18) One of the workers was found
smoking in packaging area of cement Stop smoking in working area. Immediately.
although smoking zones are provided Supervision of workers. 6 Days.
by Lucky cement authorities, this
Disciplinary actions to be taken 1 Week.
unsafe can lead to fire as flammable
against worker for non-compliance
packaging material was present in the
of rules and regulations of
area and may cause damage to plant
workplace. 1 Month.
and serious injuries to workers.
Install CCTV for behavioural
monitoring of employees.
19) Empty Cement bags were loaded

manually to the filling part of cement
and workers were continuously Rest breaks. 2 Hours.
bending, stooping and twisting in the Provision of proper seating 1 Day.
process which may lead to manual facilities.
handling hazards like back pain, Spinal Automation of filling process. 3 Months.
disc injuries and muscle pain. Health Surveillance. 2 Months.
20) There was haphazard storage of

cement bags in the storage area. Many Proper Vertical and inline stacking 4 Hours.
of the stacks were very high and of cement bags.
leaning forward posing hazard of fall Visual Inspection. Daily.
on the workers working nearby Keep stack size small. 1 Day.
ultimately resulting in serious injuries. Develop and follow safe systems 1 Month.
of work and standards for stacking.
21) Very few fire extinguishers were
present in Packaging and storage area Increase quantity of fire 1 Day.
and inspection record was also not extinguishers.
maintained. This negligence can prove Extinguishers should be installed 2 days.
to be catastrophic should any undesired at easily accessible locations.
fire event occurs and may increase Develop and implement inspection
chances of loss of raw material, routine of installed fire 3 Weeks.
damage to plant and equipment and extinguishers.
serious burn injuries to workers. Arrange training regarding use of 1 Month.
fire extinguishers.
22) Workers were working very close
to cement dust in packaging section Try to keep safe distance. Immediately.
without wearing suitable clothing and
Provision of clothing and adequate 2 Days.
PPEs so there was a strong possibility
PPEs like goggles and face visors
of contact of dust with skin and eyes
to protect direct contact with skin
which can lead to skin irritation,
and eyes.
dermatitis and eye irritation.
Supervision. 1 Week.
Training. 3 Weeks.
Develop safe systems of work. 1 Month.
23) Inappropriate First Aid facilities Provide first aid kits as per 1 Day.
were found as there were no separate requirement of subjected
rooms for first aid treatment and first workplace.
aid kits were also not suitable for the Assigning duties of first aid 1 Week.
foreseeable injuries in the workplace. treatment to competent worker.
Responsibility of first aid treatment Provide basic level training. 2 Weeks.
was also not assigned to any member Provision of separate first aid 2 Months.
of working staff. This can increase rooms.
chances of infection should any injury Routine inspection of first aid kits 2 Months.
takes place to worker. and housekeeping of first aid
rooms.
Ensure provision of Refresher 2 `Months.
training.
24) Working in cement industry is a
stressful work because of excessive
Rest Breaks. 2 Hours.
workload, high demand and long
Job Rotation. 1 Month.
working hours leading to headaches,
fatigue, mood swings and other Providing rest rooms. 1 Month.
psychological issues. Introducing stress management 2 Months.
programs.
Health Surveillance. 2 Months.
25) Good welfare facilities were
provided to workers like clean drinking
water, neat washrooms, Hygienic Good practice and should be Continue.
eating and hand wash facilities. continued.
26) Stagnant water was found on one

corner of clinker silos area which can Remove the stagnant water. Immediately.
incubate bacteria and cause ill health Housekeeping routine. Daily.
diseases like malaria and dengue to the Routine Inspection of workplace. Every Week.
people working around.
27) Led TV was placed in admin office

and bare wires were put in the socket Use plug to connect wires to Immediately.
without any plug, there was also a joint socket.
in the cable that was not insulated Ensure tight connection. Immediately.
properly presenting hazard of electric Replace the damaged wire. 1 Day.
shock, spark, fire and explosion which Routine inspection. Daily.
can lead to severe personal injuries. Periodic Inspection. 1 Month.
28) Waste management procedures
were not up to the required standards as Remove the unwanted bags from Immediately.
lots of torn cement packaging bags and packaging area at once.
are other items were present in Install more waste bins. 1 Week.
packaging area which were of no use Develop suitable waste 3 Weeks.
but were covering lots of space and management plan for early
could work as flammable material in disposable of junk material.
case of ignition source provided. Hire a supervisor to ensure early 1 Month.
Adding to that, very few quantities of disposal of waste to designated
waste bins was present in the area. This disposal areas.
can lead to damage to plant and
equipment, loss of raw product and also
endangers life of workers.
29) Abundance of coal was present in

storage area and no warning signs or Use signs like Unauthorized 3 Days.
any other precautionary measures were access Prohibited to prevent
taken to prevent easy access, it could be unwanted entry.
a significant combustion material if Keep as minimum quantity of coal 1 Week.
ignition source is found. It can be the in storage area as possible.
cause of serious property and
Routine inspection. 1 Month.
equipment damage and could also lead
to fatal burn injuries and asphyxiation
due to smoke in case fire takes place.
30) Complaint box was present at

different locations throughout the
workplace so that workers can raise
Good practice and should be Continue.
their concerns regarding issues found at
continued.
workplace.
GC3 THE HEALTH AND Candidates report
template
SAFETY PRACTICAL APPLICATION
Sheet number of _____
Student number: 00382919
Location: BESTWAY CEMENT HATTAR HARIPUR Date of review: 01/05/2017
Introduction including ove rvie w of a re a inspe cte d a nd a ctivitie s ta king

p l a ce
Bestway Cement Limited is part of the Bestway Group of the United Kingdom. It is located near
Suraj gali road, driving from Taxila to Bestway cement Hattar Industrial Estate, Hattar District
Haripur, KPK, Pakistan. In early 1994, plant started producing cement. Current production capacity of
plant is 1.15 million tonnes per annum. It has manpower of 280 at its peak production time.
Companys vision is to produce high quality cement at the lowest cost possible; it is companys aim to
achieve 30% of market share of North Zone of Pakistan in the longer term.
A visit was conducted to Bestway Cement Limited Hattar on 29 th April, 2017 at 02:00 PM for review
of Health, Safety and Environmental performance of cement factory. The visit took 60 minutes and it
was good learning and informative experience. Visit was conducting in following areas:
Quarrying area
Crushing Unit
Conveyer Units
Raw Mill
Clinker Production area
Clinker Silos
Kiln
Cement Production
Packing area
Parking
Admin office
Following activities and procedures were observed during the visit:

Drilling
Work at height
Explosion
Crushing of big rocks
Transfer of small rocks balls through overhead conveyers
Clinker Production
Heating Process in Kiln
Vehicle movement and Parking
Heavy Machinery Operations
Packing of cement in bags
Electrical Safety measures
Emergency escape procedures
Fire Prevention Procedures
Waste Management procedures
All above activities and procedures were observed and inspected with reference to health and safety
measures taken and need for improvement. Environmental protection was also kept in mind during the
visit.
Exe cutive Summary

Bestway Cement is a well renowned name in the cement manufacturing industry and it was a good
learning experience visiting the Hattar plant. Company is very keen to follow health and safety
standards and legislation, along with continual improvement of health, safety and environment in the
workplace.
Satisfactory Health and Safety measures were in place. Compliance to Health and Safety standards was
observed, i.e. providing welfare facilities like clean drinking water, washroom facilities, rest rooms etc.
Suitable and sufficient parking, adequate light levels throughout workplace and encouraging worker to
highlight areas of concerns through providing complaint box system are also improving the safety
culture in the organization.
However, Improvement and safe working is required in rotary kiln operations, manual packaging,
vehicle maintenance, machine guarding, first aid provision, working at height, smoking in workplace,
electric and fire safety, working in hot environment, storage of coal, stacking of cement bags, edge
protection, machine guarding, FLTs reversing, waste management, vibration and noise due to heavy
machinery and vehicles and airborne dust exposure. Lack of safe systems of work and visual
inspections routines is also increasing overall risk
Non-compliance with standards is observed in some of the activities and working procedures followed
to perform the tasks which can cause minor or fatal injuries to workers, adverse health effects like
malaria, dengue, NIHL, asthma, dermatitis and other physical and psychological problems leading to
absenteeism, sick leaves and high staff turnover rate. Damage to plant, equipment and machinery, fire
and explosion can also take place due to negligence. All these problems add to the total direct and
indirect cost of organization.
Incidents taking place due to these non-compliance acts can have other negative implications like bad
industrial and business reputation. Enforcement action can also be taken by the relevant authorities
along with prosecution in criminal courts resulting in fine or imprisonment.
All highlighted issues should be addressed at earliest by applying suitable control measures. Other
sections of report including Observations sheet, recommendations, legislation breaches, precautionary
measures, control measures, resource implications, conclusion and main findings of the inspection and
cover these issues in detail.
Ma in findings of the inspe ction
1. Observation # 1,5,7,17,20
Work at Height, Fall of Object and Fall of Person:
Hazards of fall of person, fall of object from height and trip and fall were present in multiple
activities like Rotary Drill operations in quarry, unprotected edge in quarrying area, overhead
conveyer belts without appropriate side guards, damaged stairs corner in clinker cooling area and
uneven stacking of cement bags in cement bags storage area.
Above highlighted hazards can cause minor or fatal injuries to workers and damage to heavy
machinery working in quarry.
These hazards can be controlled or even can be eliminated by developing and adopting safe
system of work regarding all activities that have potential to cause harm and injuries, installing
protecting guards where necessary, providing hard hats to workers, installing adequate protection
on unprotected edges, providing experts supervision, ensuring periodic maintenance of
machinery, equipment and workplace and developing and implementing inspection routines.
All these safe measures can be taken under budget of 0.3 Million PKR approximately. Major
amount of budget will be utilized in Installing protective guards on all overhead conveyers
costing 0.15 Million PKR and protecting the edges costing 85,000 PKR approximately.
Breaches of National and International Legislation:

THE Factories ACT 1934 (33-D (a)) Pakistan.
(Stairs Safety)
Work at height reg.2005.
International Labour Organization
ILO Convention 1988 (C167, Article 13)
(Safety of workplace)
(Work at height)
OC 200/31 Regulations (Reg#6, Reg#10)
(Avoiding of work at height, Falling Objects)
2. Observation# 6,13,22
Airborne Dust and Environmental Hazards:
Insufficient measures to cater airborne dust particles of limestone, cement and silica can cause
irritation to eyes, nose and throat. These particles can also cause serious respiratory track issues
like asthma, silicosis, lung cancer. Cement is a skin irritant and can lead to skin irritation and
dermatitis.
Excess amount of Carbon dioxide(CO2) gas emission due to use of coal as energy source in
Rotary kiln pollutes the atmosphere and can be cause of climate change and ill health effects
like dizziness, headaches and difficulty in breathing.
Provision of protective clothing and other PPEs like goggles and face visors can prevent direct
contact with skin and eyes. Suitable Respiratory protective equipment can be useful to avoid
respiratory track and breathing issues. Providing health surveillance to workers is another
proactive measure. Use efficient energy sources like natural gas can be used to reduce CO2
emission in atmosphere.
Total budget required for Respirators ,other PPEs and health surveillance of workers will be 0.12
Million PKR approx. Cost of maintenance of Rotary Kiln for enhancing efficiency is about 0.1
Million PKR.

THE Factories ACT 1934 (16-D) Pakistan.
(Hazardous Substance)
(Regarding PPES)
ILO Convention 1988 (C148, Article 2-a)
(Air Pollution)
3. Observation# 4,8,10,14
Vibration, Noise Hazard of Vehicles and Machinery and Direct Contact Hazard of
Machinery:
Heavy Machinery and Vehicles used in quarrying, crushing and Production process were making
excessively loud Noise and Vibration. Machine guards were not used in packaging section and
extreme temperature conditions were observed in working area of Rotary Kiln.
Noise and Vibration can have adverse health effects like tinnitus, temporary ringing in ear,
temporary hearing loss or even NIHL, joints damage, Spinal disc damage, blanching etc. Hazard
of contact with dangerous part of packaging machine, Extreme temperature conditions can cause
dehydration, muscle cramps and heat stress.
Maintenance of Vehicles, Equipment and Machinery, installing suitable guards, job rotation and
provision of ear defenders or ear plugs can control the OEL of vibration and noise at workplace.
Cool refuges and sufficient quantity of isotonic drinks should be provided to mitigate effects of
extreme temperature conditions.
Maintenance cost of Vehicles, Machinery and Equipment along with installation of safety guards
will be 0.4 Million PKR approx. Other cost will be 0.15 Million PKR that would mostly be
spent on making cool refuges.

THE Factories ACT 1934 (33-D) Pakistan.
(Safety of machinery)
ILO Convention 1988 (C167, Article 17-1(b))
(Maintenance of machinery)
ILO Convention 1977 (C148, Article 2-b,2-c)
(Noise and Vibration)
Occupational Safety and health Act 2006 Act-9 (6, 65, 66, 67)
(Unfenced machinery part
4. Observation# 11,18, 21,27,29
Fire and Electricity Hazards:
Smoking in packaging area can be cause of fire, presence of very few fire extinguishers in
packaging area, abundance of coal stocked in storage area and jammed door of emergency escape
route could increase the gravity should any fire incident takes place. Un-covered High voltage
electric panels and bare wires in the electric socket present electric shock and fire hazards.
All above malpractices could become cause of severe damage to plant, loss of raw material and
fatal serious burn injuries to workers.
Suitable control measures would be installing sufficient quantity of fire extinguishers, storing
minimum quantity of coal in storage area, clearing the jammed door, supervision of competent
personnel in working area, routine housekeeping, periodic monitoring, adopting safe systems of
work, developing inspection routine, covering and applying LOTO to High voltage Electric
Panels and replacing the damaged wire.
Budget required to install sufficient quantity of fire extinguishers is 85,000 PKR approx.
Approximately 18,000 PKR would be enough for catering highlighted electrical hazards.

THE Factories ACT 1934 (25-3 ) Pakistan.
(Safe Escape door)
(Fire Precautions)
(Electric Safety)
Occupational Safety and Health Act 2006 (Act-9 Part-XI)
(Fire Safety)
Manual Loading and Collision Hazards:
Empty Cement bags were loaded manually, tyres of one of the dumpers were in worn out
condition which. Forklift truck in the packaging area was reversing without audible reversing
alarms and flash beacons to warn the pedestrians, there was no banks man either to guide the
driver.
Continuous bending, stooping and twisting may lead to manual handling hazards like back pain,
spinal disc injuries and muscle pain. Slip or collision incident can take place due to poor road grip
of dumper. Careless practice of reversing Forklift truck without adequate control measures can
lead to collision with fixed objects and pedestrian working in the vicinity.
Automation of packaging process, replacing tyres of dumper on priority and installing flash
beacons and audible reversing alarms to forklift truck as well as hiring a competent banks man
are suitable control measures to minimize or eliminate collision hazards.
Automation of packaging process will cost 1.5 Million. Dumper tyres replacement will cost 0.12
Million PKR approx. Cost of installing flash beacons and audible reversing alarms to forklift
truck will be about 75,000 PKR.
THE Factories ACT 1934 (27) Pakistan.
(Working near Machinery)
The Guarding of Machinery Convention (1963)
(Transport)
First Aid Facilities, Biological and Waste hazards:
First Aid facilities were not suitable and sufficient for the foreseeable injuries; stagnant water was
found on one corner of Clinker silos area .Waste management procedures were not up to the
required standards as lots of torn cement packaging bags were present in packaging area. Very
few quantities of waste bins were present in the area.
Insufficient first aid facilities lead to infections ,stagnant water incubate bacteria and cause ill
health diseases like malaria and dengue, Large quantity of defected cement packaging could
easily become flammable material in case of ignition source provided.
Providing first aid kits and separate rooms for first aid as per requirement of subjected workplace,
removing stagnant water and unwanted cement bags, developing visual inspection routines,
installing sufficient quantity of waste bins can be efficient control measures of biological waste
hazards highlighted.
First Aid Kits and separate rooms will have a cost 0.25 Million PKR. Installing waste bins that
are suitable for intended purpose have approx. cost of 48,000 PKR.

THE Factories ACT 1934 (13) Pakistan.
(Cleanliness)
(Biological and waste health hazards)
(First Aid)
(Working Environment)
Occupational Safety and health Act 2006 (Act-9, Part-XII).
Conclusions
Inspection was carried out at different sections of the Cement factory. Overall satisfactory Health and
Safety measures are in place like welfare facilities provided, designated and well maintained parking
areas and availability of complaint box for workers to voice their concerns are some of the good
practices and shall be continued, but there always remains a room for improvement.
Some of the activities require special attention as they pose a serious threat to Health and Safety of
workers in the organization including Quarry drilling, Use of explosives for breaking heavy rocks in
quarry area, Rotary kiln operations, Crushing of big rocks, Clinker production, manual packaging,
vehicle maintenance, machine guarding, safe systems of work and first aid provision. Further negligence
can result in cancellation of certification with International standardization bodies as well as necessary
enforcement action can be taken by local authorities against the organization.
Immediate action is required to eliminate or mitigate hazards of fall of person, fall of object from height,
rugged dumpers tyres, smoking in workplace, hot environment near kiln, unprotected edges in
quarrying area, workplace stress, uneven stacking of cement bags, airborne dust and chemicals, heavy
machinery and vehicles producing noise and vibration, abundance of coal in storage area, jammed door
of emergency escape route, reversing FLTs, electric shock due to damaged wire and open electric
panels, fire due to inappropriate fire prevention and fighting measures, stagnant water in clinker silos
area and waste management. These hazards can result in unwanted incidents like serious or fatal injuries
which include muscle pain, severe burns, cuts and grazes, fractured bones, Vertebrae column injury and
other loss time injuries. Loss or damage of plant, equipment and machinery, ill health issues like NIHL,
asthma, dermatitis and psychological issues can also be consequences if these hazards are not controlled.
Unwanted incidents happening due to all the mentioned hazards can also become cause of loss of
production time, increase in sick leaves, absenteeism rate and staff turnover rate. Legal actions can also
be taken due to non-compliance including enforcement actions by local authorities and prosecution in
criminal courts which can result in fines to the company and even imprisonment of responsible
individuals such as Directors or Senior managers of the organization. Company can save foreseeable
direct and indirect cost arising from these hazards by taking proactive measures; by introducing
adequate control measures.
All the hazards should be eliminated or reduced to a level at which they are no more harmful to health
and safety of workers. Employer has the responsibility to provide safe working environment, procedures
and equipment to the workers as far as reasonably practicable. Employer should also ensure positive
health and safety culture in the organization by introducing training programs, conducting inspections
and monitoring workplace activities. Suitable budget must be allocated to introduce control measures in
order to address all the highlighted issues. Possible control measures along with timelines and predicted
cost are mentioned in the observation sheet, main findings and recommendation section of report which
can be followed to improve overall health, safety and environment of the Cement Plant.
Recommendations
Recommendation Likely resource Priority Target date

implications
Main Finding # 01
Install protective guards on Approximate cost of guards, edge
overhead conveyers. protection, repair damage to High 2-Months
Protect the unprotected stairs, providing hard hats and
edges at quarry area. developing safe system of work
Repair damaged stairs. will be 0.3 Million PKR.
Provide hard hats to
workers. 10 trained workers required.
Develop and implement
safe system of work.
Main Finding # 02
Provision of face visors. Predicted cost of RPEs, PPEs,
Ensure availability of maintenance of kiln AND Health High 3-Months
RPEs as required. surveillance of workers will be
Maintenance of Rotary 0.22 Million PKR.
Kiln.
Health Surveillance. 4 trained workers required for
maintenance.
Main Finding# 03
Maintenance of vehicles Cost of maintenance of
and machinery. machinery and vehicles, machine High 3-Months
Provide cool refuges. guards and cool refuges will be
Install machine guards. 0.55 Million PKR.
5 trained workers required.
Main Finding# 04
Install sufficient quantity Possible cost of installing fire
of fire extinguishers. extinguishers and addressing High 1-Month
Cover the Electric Panels electrical issues will be 0.1
and apply LOTO system. Million PKR.
Replace damaged wire.
Hire competent supervisor. Hire Competent Supervisor.
Main Finding# 05 0.2 Million PKR will be the
Automation of Packaging approx. cost of automation of
Process. process, replacing tyres of High 2-Months
Replace dumper tyres. dumper and installing flash
Install flash beacons and beacons and audible reversing
audible reversing alarm to alarm to FLTs.
FLTs.
Hire a banks man. 5 Trained workers required.
Hire trained banks man.
Main Finding# 06
Provide First Aid Kits. First Aid Kits and separate first
Provide First Aid rooms. aid rooms and installing waste High 2-Months
Removing stagnant water bins will have a approx. cost of
and unwanted cement bags. 0.255 Million PKR.
Installing sufficient
quantity of waste bins.

GC3 Report (Raja Aammad)

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GC3 THE HEALTH AND Candidates observation

SAFETY PRACTICAL APPLICATION sheet

Sheet number of _____

Student name:______ Raja Aammad Masood Satti_________ Student number: ____00382919______

Place inspected:_________ BESTWAY CEMENT HATTAR___ Date of inspection: 29/04/2017

Observations Control measures Timescale

3) Dumpers were carrying the heavy

4) Heavy Machinery and Vehicles used

6) Dust hazard was present throughout

8) Raw material is moved from raw

9) Door of Emergency Escape route

10) Machine guards were not used in

12) Designated Parking areas were

13) Coal used to run Rotary kiln and

15) Adequate Light levels were

16) Forklift truck in the packaging

19) Empty Cement bags were loaded

20) There was haphazard storage of

26) Stagnant water was found on one

27) Led TV was placed in admin office

29) Abundance of coal was present in

30) Complaint box was present at

Sheet number of _____

Student number: 00382919

Location: BESTWAY CEMENT HATTAR HARIPUR Date of review: 01/05/2017

Introduction including ove rvie w of a re a inspe cte d a nd a ctivitie s ta king

Following activities and procedures were observed during the visit:

Exe cutive Summary

Breaches of National and International Legislation:

Breaches of National and International Legislation:

Breaches of National and International Legislation:

Breaches of National and International Legislation:

Breaches of National and International Legislation:

Recommendation Likely resource Priority Target date

5 trained workers required.

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Student name:__ Raja Aammad Masood Satti_ Student number: 00382919__

Place inspected:_______ BESTWAY CEMENT HATTAR_ Date of inspection: 29/04/2017