WPA Sample Report

SAFETY AND HEALTH OFFICER EXAMINATION
3/2003
PAPER III
PART 2 : WORKPLACE ASSIGMENT
HAZARDS IDENTIFICATION, RISK ASSESSMENT AND RISK
CONTROL MEASURES
KUALA LUMPUR CONVENTION CENTRE PROJECT
SUNWAY CONSTRUCTION BERHAD
Prepared by
YATI AHMAD
(NS2567)
Workplace Assignment Earthing Installation at Raft Foundation Area
Kuala Lumpur Convention Centre Project
Table of Contents
Contents Page Number
Acknowledgements v
1. Abstract 1
2. Introduction
2.1 The Company 2 3
2.2 The Selected Project 4-5
2.3 Organization Chart 6
2.4 Activities and Work Processes 7
2.5 Work Environment 8
2.6 Job and Tasks 8
3. Objective 9
4. Methodology
4.1 Identifying Hazards 10 - 14
4.2 Technique Used to Assess and Evaluate 15 18
The Risks
4.3 Hazards Prioritisation 19
ii
Table of Contents
Contents Page Number
5. Results
5.1 Hazards Listing 20
5.2 Critical Hazard and Its Effect to the Safety 21
and Health of Workers
6. Recommendation
6.1 Control Measures 24
6.2 Programme Review 25
6.3 Conclusion 26
7. References 27
8. Appendices 28
Appendix I Project Site Location
Appendix II Built-up Area Plan
Appendix III Companys organisation chart.
Appendix IV Kuala Lumpur Convention Centre Project
Team Organisation Chart
iii
Table of Contents
Contents
Appendix V Kuala Lumpur Convention Centre Site
OSH Organisation Chart
Appendix VI Summary of Master Work Programme
for Kuala Lumpur Convention Center Project
Appendix VII Photos for earthing installation at raft foundation area
Appendix VIII Job Safety Analysis for Earthing Installation.
iv
Acknowledgements
I would like to express my sincere appreciation and gratitude to Sunway Construction
Berhad for giving me an opportunity to attend the Certificate of Safety and Health Officer
Course organized by National Institute of Occupational Safety and Health (NIOSH).
I also wish to extend my thanks to Mr Phillip Varughese, Sr. Manager of Occupational
Safety and Health in Sunway Construction Berhad for the advice, guidance and
encouragement throughout my career in Occupational Safety and Health.
The special thanks also dedicated to Mr Bernard Engineer of Pekat Technology Sdn
Bhd, Mr Selva Rajah and Mr Rusmin Abd Ghani Safety & Health Executives of Sunway
Construction Berhad, Mr Michael Tan and Mr Beh Yen Fei Planning Engineers of Sunway
Construction Berhad, Mr Hung Siang Wei Engineer of Sunway Engineering and the other
colleagues of Kuala Lumpur Convention Centre Project, Sunway Construction Berhad for
their support and encouragement throughout the preparation of this Workplace Assignment.
The last but not least, a warmest appreciation to my husband Mr Haidhir bin Kamarul
Bahrin for the invaluable love, encouragement, caring and support.
v
____________________________________________________________________________________________________
1. Abstract
This Workplace Assignment is a study to identify the hazards, assessing the risks and
recommending the control measures for Earthing Installation at Raft Foundation at Kuala
Lumpur Convention Centre Project, a project awarded to Sunway Construction Berhad.
The study has identified several hazards while installing the earthing system at raft
foundation area in this project. Using the Risk Ranking Table, hazards for trip and fall was
found as critical. This hazard may lead to an injury to the workers.
The slippery and unstable surface of rebar may contribute to the trip and fall hazard.
To eliminate or minimise this hazard, the control measures recommended is to ensure good
housekeeping. Proper safety shoes will assist in minimising the trip and fall hazard.
1
2. Introduction
2.1 The Company
Sunway Construction Berhad (SUNCON) was first incorporated as Sungei
Way Quarry Sdn. Bhd in 1976. It was subsequently re- named Sungei Way
Quarry and Construction Sdn. Bhd in March 1981 to reflect its growing
involvement in the construction industry. During the Groups corporate
exercise in 1984, SUNCON changed its name to Sungei Way Construction
Sdn. Bhd. In 1996, it was converted into public company, and it was listed in
the main board of the Kuala Lumpur Stock Exchange (KLSE) on 12 June
1997. In line with the change of the Sunway Group, SUNCON acquired its
present name on 13 December 1999.
SUNCON has, over the years, established itself as a reputable contracting
concern having undertaken a wide range of turnkey building and civil
engineering projects. Its track record features of buildings, roads, bridges,
infrastructure works, etc. This was realized through the application of creative
thinking, innovative methodology coupled with the synergistic diversification
of the Sunway Group, undoubtedly one of Malaysias most dynamic and well-
diversified conglomerates.
SUNCON is registered Class A Contractor with Pusat Khidmat Kontraktor. It
is also registered as a Grade 7 entity with the Construction Industry
2
Development Board of Malaysia. The Companys clients range from
governmental sectors to private organizations and individuals.
SUNCON aspires to be a progressive construction company both in the
regional and international arena. The management of Occupational Safety and
Health has been considered as an important key performance to the company.
As an OHSAS 18001 certified company, SUNCON is committed to ensure the
providing and maintaining a safe and healthy working environment by
creating a corporate culture for the overall well-being of the employees and
the community.
2.2 The Selected Project
3
This Workplace Assignment will study the hazard identification, risk
assessment and risk control measures in one of the latest building construction
activities done by SUNCON. The selected project worth RM 550 million,
named as Kuala Lumpur Convention Centre Project is located in the Kuala
Lumpur City Centre area.
The project is to be an international exhibition and convention centre
to attract and conduct large international standard convention and related trade
shows and exhibition.
The details of project :
PROJECT TITLE
Kuala Lumpur Convention Centre at Kuala Lumpur City Centre, Kuala
Lumpur, Wilayah Persekutuan Design, Construction and Completion of
the Main Building Works
LOCATION
Bounded by Jalan Pinang & Jalan Kia Peng, the KLCC Metropolitan Park,
the Mandarin Oriental Kuala Lumpur and the Menara Exxon-Mobil
(Appendix I Project Site Location)
4
BUILT-UP AREA & CAPACITY
The Convention Centre is build into 4 sections i.e West Wing, Center Core,
East Wing and Plenary Hall with 2 basement levels and 4 levels (GL L4)
above ground
(Appendix II Built-up Area Plan)
CONTRACT DETAILS
Contract Sum : RM 549.3 million

Contract Award : 16th September 2002
Site Possession Date : 17th September 2002
Contract Period : 131 weeks
Sectional Completion : 24th December 2004 (East Wing, West
Wing & Centre Core)

Final Contract Completion : 21st March 2005 (Plenary Hall)
EMPLOYER : Kuala Lumpur Convention Centre Sdn Bhd
PROJECT MANAGER : KLCC Projeks Berhad
MAIN CONTRACTOR : Sunway Construction Berhad
KEY TEAM MEMBER : Taisei Corporation Japan
(TECHNICAL ADVISORY)
2.3 Organisation Chart
5
Appendix III describes the companys organisation chart.
Appendix IV describes the Kuala Lumpur Convention Centre Project Team
Organisation Chart
Appendix V describes the Kuala Lumpur Convention Centre Site OSH
Organisation Chart
2.4 Activities and Work Processes
6
Below is the common flow chart for SUNCONs work processes
Tendering
Processes
Yes
Design
and Build Design and
? Development
No
Pre Construction
and Planning
Procurement
Construction
Post Construction
Hand Over to
Clients
Ref : SUNCON Quality System Product Realization
As a construction company, details of work activities and schedule are
vary from project to project. The details of work activities and schedule for the
project also known as a Master Work Programme. This Master Work
7
Programme will be planned by Planning Department and acts as a guidance
for the project implementation.
Appendix VI describes the Summary of Master Work Programme for
Kuala Lumpur Convention Center Project. With reference to this Summary,
one of the current active jobs is Raft Foundation, which cover the activity of
earthing installation. This Workplace Assignment had selected this activity to
study the hazards identification, risk assessment and recommend the control
measures for eliminating or minimising the risks.
2.5 Work Environment
Kuala Lumpur Convention Center is a building construction works
with 2 levels underground and 4 levels above ground.
2.6 Job and tasks
For each job activity, Method Statement was established as guidance
for the workers to do the tasks. Method Statement brief step by step the tasks
and will be read together with Job Safety Analysis.
3. Objectives
This Workplace Assignment objectives are
8
a. To identify the hazards in the Earthing Installation at Raft Foundation area at Kuala
Lumpur Convention Centre Project .
b. To assess the risks that might raise from the hazards identified in the Earthing
Installation at Raft Foundation area at Kuala Lumpur Convention Centre Project .
c. To recommend the control measures to minimise or eliminate the risks from the
identified hazards in the Earthing Installation at Raft Foundation area at Kuala
Lumpur Convention Centre Project .
4. Methodology
4.1 Identifying Hazards
9
Hazards identification in the Earthing Installation at Raft Foundation area at
Kuala Lumpur Convention Centre Project was done with the implementation
of Job Safety Analysis (JSA).
Job Safety Analysis is a tool to identify hazards, assess the risks and
recommend the control measures for the work activities that will be done. The
steps of JSA for identifying the hazards are by breaking down the job into its
components parts in an orderly and chronological job sequences followed by
identifying the hazards for each component. Then, the risks will be assessed
and evaluated. The risk ranking will give the guideline of the urgency of
action and control measures.
For Earthing Installation at Raft Foundation area at Kuala Lumpur Convention
Centre Project, the hazards identification steps were done by the discussion of
sub contractor personnel (Operations), M&E Engineer and OSH personnel.
With reference to the Method Statement of Earthing Installation at Raft
Foundation area, the jobs sequence for this activity are :
1. Installation of earth electrode (copper)
10
i. Identify location
ii. Drive in the copper bond earth electrode using hammer jet
iii. Measure earth resistance and record
iv. If earth resistance do not achieve desired value, insert rod coupling to
joint first electrode to second electrode and drive in second electrode.
Measure earth resistance again.
v. If earth resistance achieve desired value, repeat step i to iv until all
electrode planted.
2. Installation of horizontal earth cable (copper)
i. Identify location for laying cable (horizontal)
ii. Lay cable along the routes
iii. Repeat until all earth cable installed.
3. Exothermic Welding of horizontal earth cable to electrode
i. Insert the graphite mould and place both electrode and cable and
ensure no gap between the jointing part
ii. Place retaining disc and pour in welding powder
iii. Use flint gun to ignite the starting powder
4. Installation of vertical cable via column reinforcement bar
i. tighten the vertical earth cable with wire tie to the :
a. raft foundations bottom horizontal rebar
b. raft foundations upper horizontal rebar
11
c. columns vertical rebar
ii. vertical earth cable is wire tie to column rebar at 1m interval after the
first welding point until the test point level or roof level interfacing
point.
5. Installation of test point
Appendix VII describes photos for earthing installation at raft foundation area
in Kuala Lumpur Convention Centre Project.
With the break down of the job into its component parts, the hazards can easily
be identified as in this table:
Job Sequences Hazard Identification

Potential Hazard Potential Risk
12
1. Installation of earth electrode (copper)
i. Identify location Trip and fall Minor injury
ii. Drive in the copper bond earth Vibration Diseases

electrode using hammer jet
iii. Measure earth resistance and record Trip and fall Minor Injury
iv. If earth resistance do not achieve Vibration Diseases

desired value, insert rod coupling to
joint first electrode to second
electrode and drive in second
electrode. Measure earth resistance
again.
v. If earth resistance achieve desired

value, repeat step i to iv until all
electrode planted.
2. Installation of horizontal earth cable

(copper)
i. Identify location for laying cable Trip and fall Minor Injury
(horizontal)
ii. Lay cable along the routes Trip and fall Minor Injury
iii. Repeat until all earth cable installed.
3. Exothermic Welding of horizontal earth

cable to electrode
i. Insert the graphite mould and place Crushed in Minor injury

both electrode and cable and ensure between
no gap between the jointing part
ii. Place retaining disc and pour in - Smoke Diseases

welding powder hazardous to
health
13
iii. Use flint gun to ignite the starting - Weld metal Major injury
powder spew out
- Explosion Major injury
Hot material Minor Injury
4. Installation of vertical cable via column

reinforcement bar
i. tighten the vertical earth cable with wire - Trip and fall Minor injury
tie to the :
- raft foundations bottom horizontal rebar - Crushed in Minor Injury
- raft foundations upper horizontal rebar between
- columns vertical rebar
ii. vertical earth cable is wire tie to column - Trip and fall Major Injury
rebar at 1m interval after the first welding point
until the test point level or roof level interfacing - Crushed in Minor Injury
point. between
5. Installation of test point - Trip and fall Major Injury
- Crushed in Major Injury

between
Table 1 : Hazards Identification in the earthing installation at raft foundation

area
4.2 Techniques Used to Assess and Evaluate the Risks
SUNCON has used the Risk Ranking Table to assess and evaluate the risks for
the potential hazards that were identified in the job activities.
14
Probability 1 2 3 4 5
Once in 2 Once a Once in 6 Once a Once a
Consequence years year months month week
5 First Aid 5 10 15 20 25
10 Minor Injury 10 20 30 40 50
15 Diseases 15 30 45 60 75
20 Major Injury / 20 40 60 80 100

Fracture
25 Fatality 25 50 75 100 125
Table 2 : Risk Ranking Table
Using this Risk Ranking Table, the risks for hazards identified in the earthing
installation at the raft foundation area were assessed as below :
15
Job Sequences Hazard Identification Risk Assessment

Potential Hazard Potential Risk Probabilit Consequences Risk
y Ranking
1. Installation of earth
electrode (copper)
vi. Identify location Trip and fall Minor injury 3 10 30
vii. Drive in the copper Vibration Diseases 1 15 15

bond earth electrode
using hammer jet
viii. Measure earth Trip and fall Minor Injury 3 10 30

resistance and record
ix. If earth resistance do Vibration Diseases 1 15 15

not achieve desired
value, insert rod
coupling to joint first
electrode to second
electrode and drive in
second electrode.
Measure earth
resistance again.
x. If earth resistance
achieve desired value,
repeat step i to iv until
all electrode planted.
16
2. Installation of horizontal
earth cable (copper)
iv. Identify location for Trip and fall Minor Injury 3 10 30

laying cable
(horizontal)
v. Lay cable along the Trip and fall Minor Injury 3 10 30

routes
vi. Repeat until all earth

cable installed.
3. Exothermic Welding of
horizontal earth cable to
electrode
iv. Insert the graphite Crushed in Minor injury 2 10 20

mould and place both between
electrode and cable and
ensure no gap between
the jointing part
v. Place retaining disc and - Smoke Diseases 1 15 15

pour in welding powder hazardous to
health
vi. Use flint gun to ignite - weld metal Major injury 1 20 20

the starting powder spew out
- explosion Major injury 1 20 20
17
Hot material Minor Injury 2 10 20
4. Installation of vertical
cable via column reinforcement
bar
i. tighten the vertical earth - Trip and Minor injury 3 10 30

cable with wire tie to the : fall
- raft foundations bottom
horizontal rebar - crushed in Minor Injury 2 10 20
- raft foundations upper between
horizontal rebar
- columns vertical rebar
ii. vertical earth cable is wire - Trip and Minor Injury 3 20 60

tie to column rebar at 1m interval fall
after the first welding point until
the test point level or roof level - crushed in Minor Injury 2 10 20
interfacing point. between
5. Installation of test point - Trip and Minor Injury 3 10 30

fall
- crushed in Minor Injury 2 10 20

between
Table 3 : Risk Assessment for Earthing Installation at Raft Foundation
18
4.3 Hazards Prioritisation
The hazards identified in the job sequences of earthing installation at raft
foundation were prioritised with reference to the Risk Assessment done in part
4.2.
The highest risk ranking resulted from the assessment was given the first
number of prioritisation, followed with the second and third ranking. The list
of prioritisation is as below:
No Hazards Risk Ranking
1. Trip and fall 30
2. Crushed in between 20
3. Weld metal spew out 20
4. Explosion 20
5. Hot material 20
6. Vibration 15
7. Smoke hazardous to health 15
19
5.0 Results
5.1 Hazards Listing
From part 4.0, the hazards identified in the earthing installation at raft
foundation are :
No Hazards Category
1. Trip and fall Physical hazard
2. Crushed in between Physical hazard
3. Weld metal spew out Physical hazard
4. Explosion Physical hazard
5. Hot material Physical hazard
6. Vibration Health hazard
7. Smoke hazardous to health Health hazard
20
5.2 Critical Hazard and Its Effect to the Safety and Health of the
Workers
After assessment and prioritisation, trip and fall hazards was found
as a critical hazard while doing earthing installation at raft foundation
in Kuala Lumpur Convention Centre Project. This hazard score 30
points as a result of the risk ranking.
Workers are exposed to the trip and fall hazards as they are walking on
the rebar. The rebars condition is quite slippery and is not a stable
surface for walking.
Trip and fall hazard while walking or doing work on the rebar may
lead to injury of the workers.
21
6.0 Recommendation and Review
6.1 Control Measures
The recommended control measures for hazards identified in the
earthing installation were based on the Risk Tolerance Guide and Urgency of
Action Table.
Risk Description Action Times Scale &

Ranking Urgency
0 25 Trival Relevant action is required Within 2 weeks
and records need to be kept
26 50 Tolerance Controls are required. Within 1 week
Consideration need to be
given for an effective
solution or improvement.
Monitoring is required to
ensure that the controls are
maintained
51 75 Moderate Efforts should be made to Within 4 days
reduce the risk. Risk control
measures should be
implemented within a
defined time period. Where
the moderate risk is
associated with extremely
harmful consequences,
further assessment may be
necessary to establish more
precisely the likelihood of
harm as a basis for
determining the need for
improved control measures
76 100 Substantial Work should not be started Within 1 day
until the risk has been
reduced. Measures shall be
allocated to reduce the risk.
Where the risk involves work
in progress, urgent action
shall be taken
22
101 125 Hazardous Work shall be stopped Immediately

immediately until all
measures taken is
satisfactory
Table 4 : Risk Tolerance Guide and Urgency of Action
From the part 4.3, the risk ranking for the hazards identified in earthing
installation at raft foundation activity were ranked in the Trival and
Tolerance category.
The critical hazard i.e trip and fall is under Tolerance category and
need an effective control measures and monitoring.
The recommended control measures for this hazard are:
No Hierarchy Control Measures Description
1. Elimination N/A
2. Substitution N/A
3. Isolation N/A
4. Engineering Control N/A
5. Administrative Control - Ensure housekeeping
6. PPE - Wear safety shoes
23
The control measures for the other hazards are listed in the Appendix
VIII Job Safety Analysis for Earthing Installation.
These recommended control measures will be used as training material
for the workers. The training normally done in the Tool Box Briefing *
session by the respective Supervisor.
* Tool Box Briefing : a short briefing session to workers of individual
trades lead by their respective Supervisors.
24
5.2 Program Review
The effectiveness of control measures implemented will be
monitored through:
a. Inspection or Audit result
b. Incident and Accident.
Inspection or Audit may identify the inadequate or improper
control measures. Some of the recommended control measures
may not environmental-free or may produce uncomfortably to
the workers. With the Inspection or Audit, the feedback or
responses may be considered.
While there is any incident or accident, the control measures
will be review to ensure its adequacy. The inadequate control
measures may lead to an accident.
The review and revision of control measures will be done
together of OSH personnel and respective Operational
personnel (SUNCON staff or Sub Contractor Staff or both).
The revised control measures once again will be brief to the
workers through their Tool Box Briefing.
25
6.3 Conclusions
In the earthing installation activity at raft foundation in Kuala Lumpur
Convention Center Project, the most critical hazard identified is trip
and fall. The control measures recommended will assist in eliminating
or reducing the risk that occur in the work place. Therefore, the
workers could do their works without or with a minimum risk to their
safety and health.
The minimum manhours loss due to the accident can assist SUNCON
much in ensuring on-time project hand-over to client. The benefits also
goes to minimising the uninsured cost such as minimise staff turn over,
minimise legal fees, minimise the loss time due to administrative
matters by the relevant personnel and others. This will totally benefits
SUNCON in ensuring its status as a reputable construction company.
26
7.0 References
a. Sunway Construction Berhad, 2000, OSH Manual and Procedures
b. Sunway Construction Berhad, 2002, Quality System Manual
c. Sunway Construction Berhad, 2002, Project Occupational Safety
and Health Programme Kuala Lumpur Convention Centre Project
d. Sunway Construction Berhad, 2002, Contractors Overall Schedule
e. Sunway Construction Berhad, 2003, Method Statement for
Earthing Installation (Electrical) - Kuala Lumpur Convention
Centre Project
f. Sunway Construction Berhad, 2002, Document Management
System Database - Kuala Lumpur Convention Centre Project
g. National Institute of Occupational Safety and Health, 1997, Safety
and Health Officer Course Book.
27
8.0 Appendices
28

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SAFETY AND HEALTH OFFICER EXAMINATION

PART 2 : WORKPLACE ASSIGMENT

HAZARDS IDENTIFICATION, RISK ASSESSMENT AND RISK

KUALA LUMPUR CONVENTION CENTRE PROJECT

SUNWAY CONSTRUCTION BERHAD

Contents Page Number

2.1 The Company 2 3

2.2 The Selected Project 4-5

2.3 Organization Chart 6

2.4 Activities and Work Processes 7

2.5 Work Environment 8

2.6 Job and Tasks 8

4.1 Identifying Hazards 10 - 14

4.2 Technique Used to Assess and Evaluate 15 18

4.3 Hazards Prioritisation 19

Contents Page Number

5.1 Hazards Listing 20

5.2 Critical Hazard and Its Effect to the Safety 21

and Health of Workers

6.1 Control Measures 24

6.2 Programme Review 25

Appendix I Project Site Location

Appendix II Built-up Area Plan

Appendix III Companys organisation chart.

Appendix IV Kuala Lumpur Convention Centre Project

Team Organisation Chart

Appendix V Kuala Lumpur Convention Centre Site

OSH Organisation Chart

Appendix VI Summary of Master Work Programme

for Kuala Lumpur Convention Center Project

Appendix VII Photos for earthing installation at raft foundation area

Appendix VIII Job Safety Analysis for Earthing Installation.

I would like to express my sincere appreciation and gratitude to Sunway Construction

Course organized by National Institute of Occupational Safety and Health (NIOSH).

I also wish to extend my thanks to Mr Phillip Varughese, Sr. Manager of Occupational

encouragement throughout my career in Occupational Safety and Health.

Bahrin for the invaluable love, encouragement, caring and support.

Lumpur Convention Centre Project, a project awarded to Sunway Construction Berhad.

found as critical. This hazard may lead to an injury to the workers.

2.1 The Company

Sunway Construction Berhad (SUNCON) was first incorporated as Sungei

involvement in the construction industry. During the Groups corporate

exercise in 1984, SUNCON changed its name to Sungei Way Construction

present name on 13 December 1999.

SUNCON has, over the years, established itself as a reputable contracting

concern having undertaken a wide range of turnkey building and civil

engineering projects. Its track record features of buildings, roads, bridges,

thinking, innovative methodology coupled with the synergistic diversification

SUNCON is registered Class A Contractor with Pusat Khidmat Kontraktor. It

is also registered as a Grade 7 entity with the Construction Industry

Development Board of Malaysia. The Companys clients range from

governmental sectors to private organizations and individuals.

SUNCON aspires to be a progressive construction company both in the

regional and international arena. The management of Occupational Safety and

Health has been considered as an important key performance to the company.

As an OHSAS 18001 certified company, SUNCON is committed to ensure the

providing and maintaining a safe and healthy working environment by

2.2 The Selected Project

This Workplace Assignment will study the hazard identification, risk

activities done by SUNCON. The selected project worth RM 550 million,

named as Kuala Lumpur Convention Centre Project is located in the Kuala

Lumpur City Centre area.

The project is to be an international exhibition and convention centre