Hazard Identification & Risk Assessment (HIRA)

Activity: Loading, Unloading, Handling, Lifting & Shifting. (incl. Vehicle movement using farana) Document No:SFL/
Project Name: TATA SmartFoodz Limited - Sri city Revision No - 00

Team Conducted: Mr. R.SURESH/SRIGURURAMAN G Work Location : Ma

Contractor : CRESCON PROJECTS & SERVICES PVT. LTD., PMC : TATA Consulting Engineers Ltd / FABS Client : Tata SmartF
Prepared by : SRIGURURAMAN GURUNATHAN Reviewed by: Approved by :
Approved by:
Signature & Date:
OHS Hazard Identification OHS Risk Evaluation
(Risk = P
Sequence of Job Consequence / Impact / Possible
Sr No Hazard Existing Risk Control Measures Probability
Steps outcome
(1-5)

1.Allow vehicle reversing under supervision or

flagman
Vehicle hit to worker during
injury to person or Fatal 2.Reverse horn shall be working condition. 2
reversing
3.Vhicle fitness shall be ensured before entre to the
site.

1.Vehicle movement access shall be level and

compact.
Vehicle topple due to unsafe
injury to person and property damage 2.Vehical park at least 2 meter away from 2
access
excavation edge
3.Access shall be plan and prepared.

Materials Vehicle
1
at site.
1.Ensure driver fitness at entry gate.
Drunken drive injury to person and property damage 2.Check alcohol test by breathing analyzer by 1
security.

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 Over speed injury to person or Fatal Speed limit shall be ensured at site max 10 kmph 2

1.Ensure vehicle fitness before deployed to work.

Failure of machine/vehicle
injury to person or Fatal 2.Daily inspection shall be ensured. 2
due to poor maintenance
3.vehical document must be check before enter

Fall of person while fixing

injury to person or Lose Time 1.Use ladder
and removing of sling on the 3
Injury(LTI) 2.Use full body harness with hooking arrangement
top

1. Check the lifting tools material physical

condition
Failure of Web Sling or wire
2.Check test certificate
rope sling due to wrong injury to person and damaged to property 3
practice
3. Check the competent for riggers
4.Check safe work load for the lifting tools

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 1. Check competent level for riggers and operator
who are deployed for unloading activities.

2.Ensure fitness and

inspection for F15 crane or mobile crane as per
checklist.
3.Follow up the safe work load (SWL)and boom
Toppling of ratio as per crane load chart which is displayed in
vehicle/equipment due to injury to person & property Damage the crane. 3
over load 4. Standard illumination shall be provided at
working area and vehicle movement area during
night.
5.Ensure Permit To Work for unloading activity
6.Unloading area shall be barricade to avoid
unauthorized entry.
7.Safety signage's shall be displayed.
8.Ensure competent signalman for unloading the
materials.
Unloading of
2 material by F15
crane

1. Two guide line ropes (20 mm dia) and

minimum 3 meter length shall be used to guide the
Swing of material. injury to person & property Damage material during shifting. 2
2. The person shall be hold the guide rope at both
side

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 1.Inspect all lifting tools and tackles along with
Damage lifting tool & SWL
injury to person & property Damage 3
tackles. 2.Use only good condition lifting tools and tackles
with valid tag.

1.Material to be stacked on wooden or concrete

sleeper only.
2.Materials shall be unloaded at designated area.
Fall of materials due to
injury to person & property Damage 3. safety guide ropes must be fixed on ground 2
unsafe surface
only.
4. Safety Helmet, Jacket, Shoe along with hand
gloves to be use during work.

Slip, Trip due to obstacles in 1. Remove unwanted materials from the access.
injury to person 2
pathway 2. Safe access should be free from slippery.

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 1.Minimum numbers of person shall be allowed
for materials shifting.
2. Manual material handling procedures must be
followed.
Unloading & 3.Transportation vehicles must be used for
Shifting and materials shifting for long distances.
3
stacking of 4.Heavy materials must be unloaded and
materials transferred by using suitable equipments such as
farana,fork lift or hand trolleys.
5.2 nos tag lines rope must be used for heavy
Fall of materials while
materials unloading and shifting by lifting
unloading,shifting,transferin injury to person/Property damage 2
equipments.
g and stacking.
6.Unloading area shall be barricaded to avoid
unauthorized entry.
7.Lifting plan to be made and get approved from
competent person.
8.Adequate PPEs to be worn by the involved
person.
10.Proper racks and boxes must be in place for
storing of materials.
11.Materials must be segregated and stored in
designated areas.

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 1.Standard illumination shall be provided at
working zone
2.Double insulated electric cables are used
3.Standard DB and SDB shall be used
Lack of illumination and 4.Earthing must be provided asper electrical
4 General Personnel injury 3
Electrocution standard
5.Open wires and loose wires must be secured and
covered by insulated material.
6.Lock out and tag out system must be followed
while carrying out repair and alteration works.

1. Competent persons shall be deployed for

welding work.
2.Leather Hand gloves ,Face shield along with
welding shield and apron shall be provided for
welder and helper
3.Hot works must be carried out in designated
area.
Hot surfaces and hot
Fire and burns injury to workmen 4.All flammable/combustible materials shall be 2
particles, Heat
removed from the hot work area.
5.Area shall be barricade to avoid unauthorized
entry.
6.Fire blanket shall be used if necessary to do
work near by flammable material stacking area.
7.Keep fire extinguisher at near by at least 5 meter
distance
5 Welding activities

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 1.Machine and equipments must be inspected
before used.
2.Electrical cable routing through ELCB/RCCB
and it shall be over head or underground.
3.Cable joint shall be avoided or use industrial
Electrocution Electric shock,burns,personnel injury 2
plug top (male & Female)
4.Standard earthing must be provided for the
equipments.
5.Leather hand gloves shell be used.
6.Ensure double insulated cables with ISI mark.

1.Ensure safety guards for all rotating parts.

2.All equipments must be operated by competent
person.
Rotating parts Injury to persons 2
3.Permit to work system must be followed.
4.Machine inspection shall be ensured and display
sticker on the machine.

1.Path ways must be clear and free from obstacles.

Sharp edges and hit by 2.Sharp edges must be protected if possible.
injury to person 2
object 3.Safe material manual handling shall be ensured
4.Restrict unauthorized entry

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 1.Equipment fitness and inspection with valid tag
shall be ensured prior to the commencement of
work.
2.Daily inspection must be conducted and
equipment integrity must be ensured by the
Damage equipment and parts injury to person 2
operator and supervisor.
3.Periodic inspection must be conducted by
competent authority and must be recorded.
4.Damaged equipment must be tagged and stored
in designated area.

6 Grinding / Cutting

1.Work specific PPE shall be used ( Hand

gloves,goggles,Shields)
2.Equipment must be inspected daily for the proper
functioning and physical conditions.
Flying objects injury to person 2
3.Periodic inspection must be conducted by
competent person.
4.Safety guards must be in place for the
equipment.

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 1.Machine and equipments must be inspected
before used.
2.Electrical cable routing through ELCB/RCCB
and it shall be over head or underground.
3.Cable joint shall be avoided or use industrial
Electrocution injury to person 2
plug top (male & Female)
4.Standard earthing must be provided for the
equipments.
5.Leather hand gloves shell be used.
6.Ensure double insulated cables with ISI mark.

1.House keeping of the area must be done prior to

the commencement and completion of work
activities.
Slip trip fall injury to person 2
2.Pathways must be kept clear all the time.
3.Material stacking and storing must be done in
proper manner

1.Work at height permit to be obtained prior to the

job.
7 General 2.Job specific PPEs must be worn(safety belt along
Fall from height Personnel Injury/Fatality 2
with mandatory PPEs)
3..Work area must be cordoned and personnel
movements to be restricted

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 1.Standard illumination shall be provided for
working zone and man ,vehicle movement area.
Poor illumination injury to person 2
2.Relective sticker shall be provided for turning
area.

1.identify the utilities by utilites detector

Uder ground 2.Use PPEs(Safety shoe,guboot,Electrical hand
injury to person or Fatal and Damaged to
utilities(Electrical cable,Pipe gloves) 2
underground utilities
line,etc) 3.If identified any utilities protect the area and
ensure shutdown work

1.Machine swing unit area shall be cordned.

2.Barrication shall be provided with safety
Machine hit to workmen at
injury to person or Fatal signages. 2
swing area.
3.Avoid unauthorised entry
4.Provide Flagman / Signal man

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 1.Ensure equipment fitness before deployed to
Failure of machine/vehicle
injury to person or Fatal work. 2
due to poor maintanance
2.Daily inspection shall be ensured.

1.Safe access shall be ensured by ladder or slope

Fall of person into the with step cutting.
excavated pit.Unprotected 2.Hard barricade with warning signs
injury to person 2
area and poor illumination at shall be provided.
night. 3.Ensure standard illumination min lux at working
zone and man movement area.
Excavation by
8 Machine and
manual

1.Hard barricade with warning signs shall be

provided.
Vehicle may fall in to the pit vehicle damage and injury to person 2.Ensure standard illumination min lux at vehicle 2
movement area.
3.Vehicle speed limit control

1.Ensure water sprinkiling arrangement.

Dust generation Health injury to workmen 2
2.Use Nose mask and goggles.

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 1.Ensure nosie level monitoring max 90dB/8 hrs
Noise Ear lose to operator 2
2.Use ear plug or muff

1.Provide Slope and step cutting asper soil

condition (Refer drawing and design)
2.Remove excavated earth immediately from the
Earth may collapse due to
injury to person edge area 3.Do not keep 2
soil capacity
any materials in the edge area (1 Meter)
4.Do not allowed to water stagnation in pit area.
5.Ensure dewatering arrangement for raining.

1.Deploy flagman
2.Remove all materials and debris from the
Earth Filling by
Equipment may fall in to the excavated pit
9 machine and Property damage and injury to person 2
pit 3.Follow the work method statement
manual
4.Area shall be cordened to avoid unauthorised
entry.

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 1.Machine inspection shall be ensured
Vibration in machine Injury to person 2.Workmen shall be replaced for every 30 min 2
interval

Earth compaction
10 by soil compact Rotating parts Injury to person Safe guard shall be provied for rotating parts 2
machine

1.Ensure all electrical connection shall be routed

through ELCB/RCCB/MCB
Electrocian Fatal 2
2.Cable joint shall be avoid or male female plug to
shall be used for cable joint.

1.House keeping of the area must be done prior to

the commencement and completion of work
activities.
Slip trip fall Personnel Injury 2
2.Pathways must be kept clear all the time.
3.Material stacking and storing must be done in
proper manner

11 General
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11 General 1.Work at height permit to be obtained prior to the
job.
2.Job specific PPEs msut be worn(safety belt along
Fall from height Personnel Injury/Fatality 2
with mandatory PPEs)
3..Work area must be cordoned and personnel
movements to be restricted

1.Standard illumination shall be provided for

working zone and man ,vehilce movement area.
Poor illumination injury to person 2
2.Relective sticker shall be provided for turning
area.

1.Do not keep any materials on the working

Fall of materials injury to person & property Damage platform bucket. 3
2.Ground level area shall be provided.

1. Ensure full body harness for workmen with

hooking arrangement.
MOBILE 2.Follow the SOP as provided for manufacturing
ELEVATED Fall of persons. Serious physical injuries / LTI. manual. 3
12 WORKING Refer equipment manual.
PLATFORM
(BOOM LIFT)

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 1.Ensure authorized and competent operator at all
time.
2. Follow the SOP for operating manual.
Failure of equipment function injury to person & Equipment Damage 3.Ensure equipment maintenances and services 3
asper operating manual instruction.
4.Daily inspection shall be ensured before allowed
to work.

1. Proper work platforms must be provided.

2.Hand rails (Top rail and mid rail ,toe guard)must
be provided for the work platforms

3. Competent persons must be deployed for

injury to person and fall may leads to
Fall of person from height
fatality
erection.
4.Safety harness must be worn by the person if the 3
work height is above 2 meters.
5.Ground level must be firm and in
same level.
6.Ladder and walkway shall be used for high
work.
7.Walkway shall be tied with steel wire

Erection of
13
scaffolding
Page 15 of 47
 1. Competent workmen shall be deployed for
erection
Erection of
13 2.Scaffold
scaffolding
structures must be inspected and ensured that
joints are properly connected.

3.Scaffold erection zone shall be restricted to avoid

unauthorized entry.
4. Ground level must be firm and in same level.
Collapse of structure while
injury to person & property Damage 5.Base plates must be used 3
erection
6.Scaffolds shall be erected asper scaffolding work
method statement.
7.Support shall be provided asper height of
scaffolding.
8.Checklist shall be ensured and use tag for safe
and unsafe for use.
9.Display of safety signage's where erection is
going
10.Wheel shall be locked condition while working
on the platform.

1.Materials must be secured .

2. Materials must be transferred hand to hand. Or
Fall of materials from height injury to person use tag line. 2
3.No loose materials shall be kept on height
surface.

Page 16 of 47
 1. Competent workmen shall be deployed for
dismantling.

2.Follow the
Fall of materials injury to workmen 2
work method statement for dismantling work
3. use tag for safe and unsafe for use.
4.All dismantle materials shall be kept in identified
location.
Scaffold
14
dismantling

1.Competent persons must be deputed for

dismantling of structure
2.Fall protection must be used for the height above
Fall of person injury to workmen 2
2 meters.
3.Use ladder and walk way for standing at height
for dismantling

Provide standard illumination for erection and

15 General Poor Illumination injury to workmen 3
dismantling activity

Page 17 of 47
 1.Follow up the MSDS procedure
2.Store in well ventilated, dry place away from
Fire hazard
sources of heat and direct sunlight
injury to person and damaged to property 2
3.Always use containers of closing lids.
4.Fire extinguisher must be in the storage area
5. Other flammable materials should be removed

1.a Health hazard, Injury to

16 Painting eyes due Follow up the MSDS Procedure safety
injury to person 2
to splash of paint, dust, rust precaution measures
etc.

1.Use tray for keep the paint and the spilled paint
immediately removed.
Slip injury due to paint 2.Barricade the painting work area
injury to person 2
spillage 3.Ensure proper housekeeping in the area
4.Store painting material at appropriate place ,and
to be tied up if the work is at height

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 1.Standard illumination shall be provided at
working zone
2.Double insulated electric cables are used
3.Standard DB and SDB shall be used
Lack of illumination and 4.Earthing must be provided asper electrical
17 General Personnel injury 3
Electrocution standard
5.Open wires and loose wires must be secured and
covered by insulated material.
6.Lock out and tag out system must be followed
while carrying out repair and alteration works.

1.Area shall be barricaded to avoid unauthorized

movement.
2. Remove all unwanted materials form the
Fall of materials. Injury to person and material damaged 3
working platform.
3.If any working related materials shall be kept in
secured with working platform.

CABLE TRAY
FABRICATION &
INSTALLATION
18
(Used for boom lift
& mobile
scaffolding)

Page 19 of 47
 CABLE TRAY
FABRICATION &
INSTALLATION
18
(Used for boom lift
& mobile 1.Ensure full body harness for workmen with
scaffolding) hooking arrangement.
Fall of persons from height. Serious physical injuries / LTI. 3
2.And allowed only height pass workers who have
passed in height work safety test.

Follow the work method statement.

Sharp edges. Injury to person 3
Use hand gloves

1.Area shall be barricaded to avoid unauthorized

CABLE PULLING
movement.
& DRESSING
2. PP rope shall be used for holding the cable along
19 (Using for boom Fall of Cables from height Injury to person 3
with workmen
lift & mobile
3.Fix the cable asper work method statement
scaffolding)
procedure.

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 1. Use PPE's for working persons
Skin related & human body related 2. Area cleaning is must.
Insects. disorders. 3. Ensure & inspect for working 3
area or pest control shall be done if required at site.

EARTH PLATE
20
INSTALLATION

Follow the work method statement.

Sharp edges. Injury to person 3
Use hand gloves

1.Area shall be barricaded to avoid unauthorized

movement.
2. Remove all unwanted materials form the
Fall of materials. Materials damaged or injury to workmen. 3
working platform.
3.If any working related materials shall be kept in
secured with working platform.
LIGHT FIXING
21 (Using for boom
lift)

1.Ensure full body harness for workmen with

hooking arrangement.
Fall of persons from height. Serious physical injuries / LTI. 3
2.And allowed only height pass workers who have
passed in height work safety test.

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 1.Area shall be barricaded to avoid unauthorized
movement.
2. Remove all unwanted materials form the
Fall of materials. Injury to person and material damaged 3
working platform.
3.If any working related materials shall be kept in
secured with working platform.
LIGHTING
22 ARRESTER
FIXING

1.Ensure full body harness for workmen with

hooking arrangement.
Fall of persons from height. Serious physical injuries / LTI. 3
2.And allowed only height pass workers who have
passed in height work safety test.

1. Cable drum shall be handled asper methodology.

2. Ensure
min speed to be maintained while rotating cable
DE COILING OF drum.
23 Fall of cable drum Personnel Injury/LTI 2
CABLE DRUM 3. Ensure cable drum support at ground level
4. Area shall be barricaded to
avoid unauthorized entry.
5.Follow the work method statement procedure.

Page 22 of 47
 1.House keeping of the area must be done prior to
the commencement and completion of work
activities.
Slip trip fall injury to person 2
2.Pathways must be kept clear all the time.
3.Material stacking and storing must be done in
proper manner

24 General 1.Work at height permit to be obtained prior to the

job.
2.Job specific PPEs must be worn(safety belt along
Fall from height Personnel Injury/Fatality 2
with mandatory PPEs)
3..Work area must be cordoned and personnel
movements to be restricted

1.Standard illumination shall be provided for

working zone and man ,vehicle movement area.
Poor illumination injury to person 2
2.Relective sticker shall be provided for turning
area.

Page 23 of 47
Page 24 of 47
on & Risk Assessment (HIRA)
Document No:SFL/TCE/CPS/EHS/RA/01
Revision No - 00 Date: 04.04.2019

Work Location : Main building area , VEG. building area, Utility building area & Site lay down area (External)

Client : Tata SmartFoodz Ltd

Approved by :

OHS Risk Evaluation

(Risk = P x S)
Severity Residual Risk Additional Control Measures Action By
Risk
(1 - 5)
( 1-25)

5 10 High Priority Tool box ,Training shall be ensured Store in charge

Medium
4 8 Tool box ,Training shall be ensured Store in charge
Priority

4 4 Low Priority Security

Page 25 of 47
5 10 High Priority safety signage's display at site Safety officer

5 10 High Priority Follow the maintenance schedule Store in charge

4 12 High Priority Tool box ,Training shall be ensured Site Engineer

Medium
3 9 Tool box ,Training shall be ensured Site Engineer
Priority

Page 26 of 47
4 12 High Priority Tool box ,Training shall be ensured Site Engineer

Medium
3 6 Tool box ,Training shall be ensured Site Engineer
Priority

Page 27 of 47
4 12 High Priority Tool box ,Training shall be ensured Site Engineer

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Tool box ,Training shall be ensured.

2 4 Low Priority Emergency response plan and Site Engineer
procedures.

Page 28 of 47
 Training for material manual
Medium handling.TBT and supervision. Safety
4 8 Site Engineer
priority posters. Emergency response plan and
procedures.

Page 29 of 47
 Tool box talk, training and supervision.
Medium
3 9 Emergency response plan and Site Engineer
priority
procedures

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 30 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Training and supervision Site engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 31 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 32 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

2 4 Low priority Tool box talk and supervision Site Engineer

5 10 High Priority Tool box talk and training Site engineer

Page 33 of 47
 Medium Check illumination level on regular
4 8 Safety officer
Priority interval

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 34 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

2 2 Low Priority Tool box ,Training shall be ensured Site Engineer

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 35 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 36 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

2 4 Low priority Tool box talk and supervision Site Engineer

Page 37 of 47
2 4 Low Priority Tool box talk and trainning Site engineer

Medium Check illumination level on regular

4 8 Site engineer
Priority interval

Medium
3 9 Tool box ,Training shall be ensured Site Engineer & EHS
Priority

4 12 High Priority Tool box ,Training shall be ensured Site Engineer & EHS

Page 38 of 47
 Medium
3 9 Tool box ,Training shall be ensured Site Engineer & EHS
Priority

4 12 High Priority Tool box ,Training shall be ensured Site Engineer

Page 39 of 47
 Medium
3 9 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 40 of 47
 Medium Tool box ,Training shall be ensured
3 6 Site Engineer
priority

2 4 Low Priority Tool box ,Training shall be ensured Site Engineer

Medium
3 9 Inspection shall be done with lux meter. Site Engineer
Priority

Page 41 of 47
 Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Medium
4 8 Tool box ,Training shall be ensured Site Engineer
Priority

Page 42 of 47
 Tool box talk, training and supervision.
Medium
3 9 Emergency response plan and Store in charge
priority
procedures

Medium
3 9 Tool box meeting and training Site Engineer
Priority

Page 43 of 47
4 12 High Priority Tool box meeting and training Site Engineer

Medium
3 9 Tool box meeting and training Site Engineer
Priority

Medium
3 9 Tool box meeting and training Site Engineer
Priority

Page 44 of 47
 Medium
3 9 Tool box meeting and training Site Engineer
Priority

Medium
3 9 Tool box meeting and training Site Engineer
Priority

Medium
3 9 Tool box meeting and training Site Engineer
Priority

4 12 High Priority Tool box meeting and training Site Engineer

Page 45 of 47
 Medium
3 9 Tool box meeting and training Site Engineer
Priority

4 12 High Priority Tool box meeting and training Site Engineer

Medium
4 8 Tool box meeting and training Site Engineer
Priority

Page 46 of 47
2 4 Low priority Tool box talk and supervision Site Engineer

5 10 High Priority Tool box talk and training Site engineer

Medium Check illumination level on regular

4 8 Safety officer
Priority interval

Page 47 of 47