'- 10 scaf foldings were build up at new warehouse construction and warehouse extension project. It was informed that these were belongs to contractors working on the project. It was noticed that all 10 scaffoldings were not posted with information on load rating to support its own weight and and at least twice the maximum intended load applied or transmitted to it. Besides, the sacafolldings were not provided with standard railing for all work platforms. Some platforms, positioned 3 to 7 meters above ground, were only put on the scaffoldings' structure without being attached firmedly to the structure. It was noticed as well that legs of the scaffolding structure was not provided with proper base plate, one was found hanging above ground. All conditions above may cause workers working on the structure falling down and get injured. It was shown that there was inspection of the erected scaffolding by an external Safety inspector on 7th May 2014 and the conclusion was not to use the scaffolding. However there was no tags attached to the scaffoldings or other effective means to inform this prohibition to prevent workers/contractors using these improper scaffoldings.
Note: It was informed that after inspection, the scaffoldings were not used due to long public holiday. The contractors are starting to work again on day 2 of audit, removing the scaffoldings.
- The Contractor built up scaffolding for warehouse roof extension, there were support used for the scaffolding building up, however this support was made of substandard wooden material, tightened with substandard line wire only and some nails were found exposed that could cause exposure of workers with sharp objects and get injured.
- There was fixed ladder installed to give access of workers to go up to the roof of Utility building e.g. for maintenance purpose, and there were 2 others attached to evaporators units at Utility area, however there was no warning signs at these points that working permit is required to protect workers from injuries from falling when working at height. KORE ES-RQ-135 requires permit program to be available when working at above 2 meters where fixed platforms and standard railings were not provided. The roof of Utility building and evaporation units was not provided with standard railings. The roof was more than 7 meters above ground while the top of evaporation units was around 3 meters above ground.
- Workers were potentially exposed to the hazards of drawning at the effluent tank and other tanks of wastewater treatment plant. There was opening of stairs to enter the effluent tank e.g. for maintenance purpose, and there was no limitation of access to prevent hazards and risks. There was no warning signage about the depth of the tank and its hazards to make people aware. Noted that the tanks have been provided with standard railings however still there were points as mentioned above that have not been included to control.
- At this effluent tank, it was observed as well that a life buoy was provided, however the rope of the buoy was too short i.e. about 40 cm only. No other rope or supporting equipment for emergency response purpose in case of workers falling into the wastewater treatment tank. Further more, the buoy was the only 1 buoy prepared for emergency case for all wastewater treatment tanks while the distance between the buoy station to, for example, equalization tank, was more than 10 meters.
- Observing equalization tank of the wastewater treatment plant, it was found that a temporary hose was installed on the edge of equalization tank where standard railing was not provided. The wastewater contained in the equalization tank was about 2 meters depth. It was informed that this temporary hose was used during trial of new anaerobic tank i.e. to transfer wastewater from anaerobic tank to equalization tank. There was no evidence shown that the activity of installing this temporary hose has complied with safety procedure to prevent falling and drowning in the equalization tank.
- At treated water settling tank of wastewater treatment plant it was noticed that standard railing has been provided for platform above the tank, however, when going up through the stairs attached to the tank, it was found that position of person standing at the end of the stairs would be to close to the edge of the tank and there was no sufficient protection e.g. guard railing for workers from falling into the tank while standing at the end of the stairs above.
- There was a pond within the premises of the Company which is functioned to collect rain water. The depth of the water in the pond was not being sured, whether it could reach 2 or 3 meters or more. This may be dangerous since it was an open pond and there was no protection of people to falling into the pond and drowning. There was no warning signs as well for the danger at this area.
- Platform beside equalization tank of wastewater treatment plant was found broken at some parts and may cause workers' legs trapped in.
- Drainage of wastewater of Production area - line 4 has been covered with grills, however some parts of the grills were found already corroded and broken and potentially cause workers' legs trapped in.
- Main stairs in office building of the Plant had been provided with standard railing as fall protection but at one side only i.e. for people going down stairs, based on the rule showed by provided arrow line. There was no standard railing provided for people going up using these stairs. It was observed as well that many times workers going up and down stairs without holding the rails as safety precaution. Stairs having only one-side guard railing were found as well at the other side of Plant office building.
- 2nd floor of sugar loading area was provided with standard railing and removable railing at the opening, however lock or similar protection equipment was not used to secure the removable railing. It was observed as well that the base of the railing was broken at some part, not firmedly tight with bolt to the floor.
- Fixed ladders were attached to water treatment plant's tanks for routine working purpose however there were no standard railing provided on the the top of the tanks to prevent workers from falling down and get injured.
- Ladder at contractor area was found being lined to the contractor's office. Supporting part of the ladder to make the ladder steady when in use was found broken. Other ladders used by Contractor as well as ladders owned by the Plant has no inspection status whether the ladder is still safe to be used, such as ladder at line 4 - Production, maintenance workshop, Utility of Injection room, and sugar storage - 2nd level.
- At Production area - Line 4 a fixed ladder was found attached to a tank, provided with safety cage. However there was distribution piping just at the end of the ladder which may cause head of worker climbing the ladders hitting the pipe.
- It was found as well at Preform - Line 8 that plastic hose was found running on the floor, transporting water from dehumidifier to the preform process, which may generate trip and fall hazards. Operator explained that this has been run like this for 2 years agon when operating Preform - Line 8.
- Before products were transported, it was observed that there were 2 operators of truck vendor covering the products with cover sheet. For this purpose the operators climbed up and standed on products which were about 2.5 meters height from the ground. It was observed that the 2 operators worn safety body harness, however the body harnesses were not anchored to the provided anchored point at the area. They just anchored it after being warned during audit site tour. It was noted that the 2 operators received safety training including about the safety procedure of working at height and the warning/punishment system if they are not complying with it. Besides, evaluation of vendor report showed that the vendor has low score for their awarenes related with use of PPE but since the total evalution report was 77 for overall performance of service quality, the vendor was still accepted by the Plant to be used.
- Water from the use of eye wash in QC Laboratory potentially generate slip and fall hazards. When function of the eye wash tested during audit, it was found that water from the eye wash spilled and spreaded on the floor of QC Laboratory.
- Platform going to preform hopper at Line 4 bottle blowing area without railing. Height is more than 2 meters. Besides, the cover of the hoper was left open as well and may casue worker falling down and get injured.