Schedule XIII

(See rule 84)

MANIPULATION OF STONE OR ANY OTHER MATERIAL CONTAINING FREE SILICA.

The following manufacturing process shall be considered as manipulation of stone or other material

containing free Silica.

a) Stone Crushers

b) Gem and Jewellery

c) Slate Pencil Making

d) Agate Industry

e) Cement Industry

f) Pottery

g) Glass Manufacturing

1. Application – This schedule shall apply to all factories or parts of factories in which manipulation of

stone or any other material containing free silica is carried on.

2. Definitions - For the purpose of this Schedule–

(a) “ manipulation” means crushing, breaking, chipping, dressing, grinding, sieving, mixing, grading

or handling of stone or any other material containing free silica or any other operation involving

such stone or material;

(b) “Stone or any other material containing free silica” means a stone or any other solid material

containing not less than 5% by weight of free silica.

PART - 1

(See rule 84)

PROCESS RISKS IN STONE CRUSHING

1. Location and lay out–

(a) No crusher plant shall be constructed or extended to within a distance of 200 m from the centre

of the proposed crusher unit to the periphery of the structure of any residence or public building

or place of worship. Exception is allowed only for store room and office room.

(b) In cases where environmental factors such as terrain and greenery are conducive to reduce

spread of pollution and where advanced technology that reduces noise and dust is employed,

the minimum distance may be further reduced to 150 m with stringent control measures such as

enclosure of crushers, classifiers, screens and other noise/dust producing units with 40 cm thick

solid wall (not hollow brick), false roofing and dust extraction system.

(c) There should be a minimum clear distance of 100 metres from the centre of crusher of one

industry to the centre of crusher of another industry.

(d) There should be a clear distance of 200 metres from the centre of the proposed crusher to State or

National Highway. For crushers fulfilling the requirements of 2nd above, the minimum distance is

reduced to 150 metres.

(e) Crushers, classifiers, screens and other noise and/or dust producing units should be housed

in buildings with solid wall (not hollow block) of minimum 23-centimetre thickness and with

suitable roofing.

2. Electrical Installations–

(a) keep the main switch box in good condition, protected from the weather in a separate room.

An appropriately sized Earth Leakage Circuit Breakers (ELCB) in all circuits shall be installed

and provide good earth or ground connection for all installations to protect the operators form

electrical hazards.

(b) Electrical cables should be laid into the underground cable trench cable trench in shock-proof

material or taken over head. Cables should be run in extra plastic conduits.

3. For work on electrical equipment insulation materials such as approved Insulation/ rubber mats shall

be provided in front of the distribution boards and main switches.

4. Lock out – tag out system shall be used for all installations which are under maintenance or repair, to

prevent others from switching on the machines while another worker is repairing it.

5. All distribution points should be marked legibly in an understandable language, marking the feeding

point, voltage, and identification number. This will help to Log-Out and make shutdown quicker in

case of emergency.

6. Required numbers of fire buckets filled with sand or portable-size Carbon Dioxide type fire

extinguishers shall be provided for use in case of fire.

7. Necessary personal protective equipment like shoes and rubber gloves shall be provided for those

deployed in electrical work.

8. Risks at Intake hoppers, bunkers for intermediate products–

(a) Wheel chokers of adequate strength and height such as raised steel girder or bump shall be

provided to prevent accidental fall of trucks into intake hoppers.

(b) Railings shall be provided for work platforms near all bunkers.

9. Risks of moving parts–

(a) Guards shall be installed around all power transmission moving parts such as shafts, couplings,

pulleys and drive belts, chains and sprockets andall other moving parts.

(b) Nip and shear points of conveyors shall be provided with permanent barrier guards. Guards must

extend beyond the in-running nips between the belts and rollers so as to make them inaccessible

from above, below and from the ends.

(c) Provide continuously accessible conveyor belts with emergency stop cables that extend the entire

length of the conveyor belt to allow access to the cable from any point along the belt.

(d) Install clearly marked, unobstructed emergency stops buttons or pull cords within easy reach of

workers in the areas where they are deployed for duty.

(e) Use prominent awareness devices such as warning signs or lights to alert workers to the conveyor

operation when it is not feasible to install guarding devices and such unguarded moving parts

shall be located away from workers.

(f) All convey or openings such as wall and floor openings, and chutes and hopper shave fencing

when the conveyor is not in use.

(g) Electrical panel room for crushers, conveyors, vibrators and all other machines in crushing unit

shall be kept under lock and key for unauthorized operation of these equipments or accidental

operation during maintenance or emergency.

(h) All accesses and aisles that cross over or under or are adjacent to the conveyor should have

adequate clearance and hand rails or other guards.

(i) Where a conveyor passes over work areas, aisles, or thorough fares, suitable guards / protected

ceilings shall be provided to protect employees required to work below the conveyors.

(j) Post appropriate hazard warning signs at all crossovers, aisles, and passageways.

(k) Conveyors should be periodically inspected and tested for safety mechanisms, such as alarms,

emergency stops, and safeguarding methods once in every month and log book shall be

maintained.

(l) Screw conveyor housing should completely enclose the moving elements of the conveyor except

for the loading and discharge points. If such guarding is not feasible, the entire conveyor should

be fenced by railing unless it is guarded by location. Alternatively, the trough side walls should be

high enough to prevent employees from reaching over falling into the trough.

10. Clothing – No worker wearing loose clothing shall be permitted to work near moving machinery and

conveyors.

11. Training –

(a) No worker shall be allowed to work in stone crushing units without attaining training on the

hazards associated with stone crushing process and safe working procedures.

(b) Refresher training on the above subject shall also be attended by all the workers once in every

year.

PART - 2

(See rule 84)

RISKS DUE TO SILICA DUST

1. Preventive Control Measures – No manipulation of stones containing silica shall be carried out in a

factory or part of a factory unless the following preventive control measures are adopted, namely-

2. Engineering Control Measures

(a) Wet Methods:

(i) Airborne Silica Dust should be minimized or suppressed by wetting or drenching the

manipulated area with water;

(ii) Machines with water drenching nozzles shall be used for drilling or cutting of concrete or

masonry;

(b) Ventilation:

(i) An effective Local exhaust system should be provided and maintained to control/ remove

silica dust from industrial processes.

(ii) Dilution/Ventilation with proper dust collection shall be used to reduce free silica dust

concentration to within the permissible limits in large areas. No direct ventilation to

atmosphere shall be resorted to.

(iii) Dust collectors/High Efficiency Particulate Air (HEPA) filter shall beset up so that dust is

removed from the source and all the transfer points to prevent contaminating work areas.

(iv) Ventilation systems should be kept in good working conditions.

3. Isolation:

(a) Effective containment methods should be used while carrying out sand blasting. Wet blasting

shall be ideal.

(b) Cutting and drilling of cabins of vehicles or machinery that might contain free silica should be

effectively enclosed and sealed.

4. Dust Control:

(a) Vacuum system with High Efficiency Particulate Air (HEPA) filter shall be used to remove dust

from work areas and from all transfer points;

(b) The belt conveyors transferring crushed material shall be totally enclosed throughout its length

of travel:

(c) Provided that such control measures as above are not necessary, if the processor operation being

carried on, is such that, the level of dust created and prevailing is within the permissible limit of

exposure specified in the second schedule of the Code and on which measurements are made

from time to time as part of air monitoring studies and records maintained.

5. Medical Control Measures:

(a) The occupier of every factory where a worker is employed in the processes specified in sub rule

clause 1 of paragraph 1, shall ensure that every worker employed is examined by a Medical Officer

within 15 days of his first employment. Such medical examination shall include pulmonary

function test and Chest X Ray – Posterior Anterior (PA) view to be compared with standard ILO

Radiographs in case of suspected Pneumoconiosis. No worker shall be allowed to work after 15

days of his first employment in the factory unless certified fit for such employment by a Medical

Officer or tested and examined by a Medical Officer outside as insisted by the Occupier and

advised by an Inspector-cum-Facilitator.

(b) Every worker employed in the said processes shall be re-examined by a Medical Officer at least

once in every twelve months. Such re-examination shall, wherever the Medical Officer considers

appropriate, include all the tests as specified in sub-paragraph (1) above except the chest X-ray

which shall be analysed by a radiologist specialized or trained in the field of analysing it with

reference to ILO Radiograph specimens on Pneumoconiosis and chest X-ray in such suspected

cases shall be carried out at least once in 3 years.

(c) Every worker employed in any of the aforesaid processes from the date on which the schedule

has come into force, shall be radiologically examined by a qualified Radiologist at the cost of the

occupier. The report of such X-ray shall be submitted to the Factory Medical Officer/Medical

Officer/Chief Inspector-cum-Facilitator within three months of the said date.

(d) If at any time the Factory Medical Officer/Medical Officer is of the opinion that a worker is no

longer fit for employment in the said process, on the ground that continuance therein would

involve special danger to the health of the worker, then he/she shall make a record of his findings

in the said Certificate and the Health Register. The entry of his findings shall contain the period

for which he/she reckons the said person unfit for work in the said process/ processes. The worker

so removed from the process shall be provided with alternate placement facilities in the factory

on job rotation basis, unless he/she is fully incapacitated in the opinion of the Medical Officer and

in that case, the person affected shall be suitably rehabilitated and compensated.

(e) No person who has been found unfit to work as stated in sub-paragraph (4) above shall be re-

employed or permitted to work in the said processes unless the Medical Officer, after further

examination, again certifies him fit for employment in those processes.

(f) A worker already in employment and declared unfit by the Factory Medical Officer/Medical

Officer shall not be allowed to work on any of the processes specified in clause I of paragraph 1,

unless he/she has been examined again using chest X-ray by a qualified Radiologist, at the cost of

the occupier and certified to be fit to work on the said processes again.

(g) For the purpose of medical supervision by the Factory Medical Officer/Medical Officer, a room

in the factory premises shall be maintained, properly cleaned, adequately lighted/ ventilated

and equipped with screen, table and with office stationery, chairs and other facilities and other

equipment /instruments including X-ray analysing arrangements for radiological examinations

and such other equipment as may be prescribed by the Chief Inspector-cum-Facilitator from time

to time shall be provided. The Factory Medical Officer so appointed shall perform the following

duties,-

(i) Maintain health register;

(ii) Undertake medical supervision and examination of workers employed in the factory;

(iii) Look after the well-being and rehabilitation of sick, injured or affected workers;

(iv) Carry out inspection of work rooms where dangerous operations are carried out and advise

the management of the measures to be adopted for the protection of health of the workers

employed therein;

(v) Educate the workers of the health hazards involved and motivate them to wear proper

personal protective equipment at workplace.

(h) The health records of the workers exposed to silicosis, shall be kept up for a minimum period

of 40 years from the beginning of the employment or for 15 years after retirement or cessation

of the employment, whichever is later and shall be accessible to workers concerned or to their

authorized representatives.

(i) For the record of medical examinations and appropriate tests carried out by the said Factory

Medical Officer, a certificate of fitness and health shall be maintained in separate register approved

by the Chief Inspector-cum-Facilitator, and shall be kept readily available for Inspection by the

Inspector-cum-Facilitator on demand.

6. Administrative control Measures

(a) Work place/Environment Monitoring: The Occupier shall ensure that work place and environment

monitoring are performed to determine the magnitude of exposure and evaluate the engineering

controls, respiratory protections, work practices and the need for medical surveillance and take

corrective control measures as and when needed.

(i) Exposure/concentration measurements shall be made in close proximity of the employee’s

actual breathing zone;

(ii) Total sampling time shall be at least 7 hours;

(iii) Work place and environment monitoring shall be repeated quarterly;

(iv) The occupier shall make available the report of dust sampling to the nearby public on demand.

(b) Training/Awareness: Workers shall be trained in the following:

(i) Health effects of free silica dust exposure;

(ii) Operations and materials that produce free silica dust hazards;

(iii) Engineering controls and way of work controls that reduce dust concentrations;

(iv) The importance of good housekeeping and cleanliness;

(v) Proper use of personal protective equipment such as respirators, etc;

(vi) Personal hygiene practices to reduce exposure;

(c) House Keeping: Maintenance of floors:

(i) All floors or places where fine dust is likely to settle and where on any person has to work

or pass occasionally shall be made of impervious material and maintained in such condition

that it can be thoroughly cleaned by any wet method or any other method which would

prevent dust from being airborne in the process and shall be done at least once during each

shift.

(ii) For removing dust, drysweeping or compressed air shall not be used but wet methods or

vacuum system with High Efficiency Particulate Air (HEPA) filter shall be used.

(iii) Dust settled over-head, over a period of time, should be removed using any wet method

before it becomes air borne again due to vibration, random air currents etc.

(d) Change room and washing facilities:

(i) Washing and bathing facilities shall be conveniently located sufficiently away from toilets and

easily accessible to the workers,

(ii) Cloak room with individual lockers shall be provided for employees to store cleaned clothing;

(iii) Workers shall take bath and change the clothing, before they leave the worksite;

(iv) Clothing worn during work shall not be cleaned by blowing or shaking;

(v) Eateries/lunch areas shall be located away from exposed areas.

(e) Display of Notices:-

(i) Warning signs/Posters shall be displayed conspicuously in a prominent place, visited by

majority of the workers;

(ii) The warning signs/poster shall list the hazards and the precautions to be taken;

(iii) The notices shall be in Malayalamas well as in the language understood by the majority of the

workers;

(f) Personal Protective Equipment: - The occupier of every factory to which this schedule apply shall

provide the following Personal Protective Equipment (PPEs) as per relevant National Standards

or International Standards and as applicable to aparticular work place.

(i) Dust Respirator or

(ii) High Efficiency particulate Air (HEPA) filter respirator or fume respirator or

(iii) High Efficiency Particulate Air (HEPA) filter respirator with full face piece or

(iv) Self-contained breathing apparatus (SCBA) or

(v) Active air respirator with a full-face piece, helmet or hood or

(vi) Self-contained breathing apparatus (SCBA) with full face piece or

(vii) Powered air purifying respirator with a High Efficiency Particulate Air (HEPA) filter.

7. Prohibition of Young Persons: No young person shall be employed or permitted to work in any of the

operations involving manipulation of stones containing silica or at any place where such operations are

carried out.

8. Exemptions:

(a) If in respect of any factory, the Chief Inspector-cum-Facilitator is satisfied that owing to the

exceptional circumstances or the lesser frequency of the processes carried onor for any other

genuine reason, may relax all or any of the provisions of this schedule necessary for protection of

the workers, by a certificate in writing, which he/she may in his discretion revoke at any time and

exempt any factory from all or any of such provisions subject to such conditions, as he/she may

think fit and specify therein.

(b) The notification of Silicosis and free silica related occupational diseases shall be strictly notified by

the Factory Medical Officer/ Medical Officer.