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STANDARD
EXCAVATION
PTS 60.2116
NOVEMBER 2010
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of
publication, of PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design,
construction, operation and maintenance of processing units and facilities. Where appropriate
they are based on, or reference is made to, national and international standards and codes of
practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants,
chemical plants, marketing facilities or any other such facility, and thereby to achieve
maximum technical and economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS
to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for
the quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, it is expected of them to follow
those design and engineering practices which will achieve the same level of integrity as
reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without
detracting from his own responsibility, consult the owner.
Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including
injury or death) suffered by any company or person whomsoever as a result of or in
connection with the use, application or implementation of any PTS, combination of PTS or
any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or
any company affiliated to PETRONAS that may issue PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed
by users to any company or person whomsoever and the PTS shall be used exclusively for
the purpose they have been provided to the user. They shall be returned after use, including
any copies which shall only be made by users with the express prior written consent of
PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in
order to ascertain how users implement this requirement.
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TABLE OF CONTENTS
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6.14 VENTILATION .................................................................................................................. 19
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10.0 AUDIT & REVIEW ...................................................................................................................... 28
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1.0 INTRODUCTION
This standard provides the minimum requirement for all excavation activities conducted at
PETRONAS and JVs (with operational controls) facilities and installations. It shall be used in
conjunction with local guidelines, regulations and statutory requirements
2.0 PURPOSE
The purpose of this procedure is to ensure that all excavation work carried out within the
OPUs/JVs does not cause harm to persons carrying out the excavation work or working within
the excavation and does not cause damage to buried services, pipelines, properties or the
environment
3.0 SCOPE
This procedure covers the minimum requirements necessary for safely carrying out
excavation work for:
Brownfield projects within the OPUs/JVs.
Greenfield projects adjacent to existing Brownfield area in OPUs/JVs.
Greenfield projects which are less than 250 meters away from existing Brownfield or
occupied areas (residential or industrial).
More stringent requirements may be implemented or may have to be adopted due to local,
state or national legislation or experience gained in specific areas of excavation.
Except for established gardens, all excavations or penetration of the ground over 150 mm in
depth require a Permit to Work and Excavation Certificate. For excavation below 1.5 meters
from ground level, it is categorized as confined space. Thus requirements under PTS 60.2105
Entry to Confined Space shall apply. If excavation is carried out in classified hazardous
location requirements under PTS 60.2123 ignition source control shall apply.
This procedure shall also apply to all piling work and borehole drilling to be carried out in all
OPU/JV
4.0 DEFINITION
Contractor: The party that carries out all or part of the design, engineering, procurement,
installation, and commissioning or management of a project or operation of a facility. Owner
may sometimes undertake all or part of the duties of the Contractor.
Owner: The party that initiates the project and ultimately pays for its design and construction.
The owner will generally specify the technical requirements. The owner may also include an
agent or consultant, authorized to act for the owner.
Excavation: The removal, boring or penetration of soil, sand, clay, or the breaking of
concrete, asphalt, or rock to a depth of greater than 150 mm, by manual, mechanical or other
means.
Fill: Material removed from the ground whether soil, sand, rock, vegetation, stones, or such
like material.
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Maximum Allowable Slope: The Angle to the horizontal at which the material in the cut face
is stable and does not fall away. The Greatest Angle Above The Horizontal Plane At Which A
Material Will Lie Without Sliding. For faces above the water table, the slope is not to exceed 1
Vertical: 1 Horizontal, and for saturated soils the slope is not to exceed 1V:1.5H
Pegging Out: A means of marking out the area to be excavated with the use of wooden or
metal pegs hammered into the ground or by the use of paint or other visual means.
Shoring System: A structure such as a metal hydraulic, mechanical or timber shoring system
that supports the sides or roof of an excavation and which is designed to prevent cave-ins.
Sheeting: The sections of a shoring system that retain the earth in position and in turn are
supported by other members of the shoring structure.
Shallow Excavation: An excavation which lowers the existing ground level to a depth of less
than 1.5 meters.
Unsupported Excavation: An excavation where the sides of the work are battered (i.e.
sloped or raked) away from the bottom of the excavation to ground level, without support.
Deep Excavation: Any excavation which lowers the existing ground level to a depth of 1.5
metres or more.
Supported Excavation: An excavation where the sides of the work are supported by
timber, steel, concrete or other materials.
Hand Digging: Excavation using spades and other hand tools, but does not include use of
spikes, pickaxes and the like, unless specifically permitted in writing.
Mechanical Digging: The use of excavators, breakers, or any similar power assisted tools.
Total Working Area: The area which is used to get the work done, i.e. the location of the
trenching, the planned area where spoil is stockpiled and the area where heavy equipment
travels.
Dewatering: The removal of water from the water table by means of a mechanical
pumping unit in order to minimize water in the excavation / soil.
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5.0 RESPONSIBILITIES
1. Senior Management
The Senior Management shall:
establish a site procedure on excavation in line with the requirements of this PTS and
local regulatory requirements
ensure adequate resources including manpower and equipment for excavation
activities are made available
ensure availability of Emergency Response Plan in the event of an emergency
ensure availability of site inspection / audit plan to check compliance to procedure
and standards
conduct review based on the incident reports, inspection, audit findings and new
regulatory requirements
2. HSE Department
The HSE Department shall:
coordinate training and promote awareness on excavation procedure to all staff and
contractors
coordinate excavation audit on a regular basis and ensure close-out of audit findings
coordinate incident investigation and disseminate the lessons learned
3. Contractor Management
Contractor management shall:
Ensure adequate resources including manpower and equipment for excavation
activities are made available.
Ensure their workers comply with the excavation procedure.
Communicate the requirements on excavation procedure to their workers including
emergency response.
Ensure availability of Emergency Response Plan for emergency during excavation.
4. Specialist Engineer
Specialist engineer shall:
Ensure an excavation which needs side support i.e. timber, steel, concrete or other
materials are properly designed and constructed.
5. Excavation Supervisor
Excavation supervisor shall ensure that:
No excavation is allowed to be carried out in an area without the prior knowledge and
approval of the Asset Owner
A written plan is prepared and submitted for asset owner approval for all excavations
which exceed 1.5 meters in depth.
All worksite supervisors are properly trained in the relevant permit to work and
safety requirements for each proposed excavation. All possible steps have been taken
to identify all underground services in the vicinity of the intended excavation and
precautions taken to prevent damage to them
a system of review and control is established to ensure that the safety
requirements of excavation activities are reviewed on a regular basis
6. Worksite Supervisor
Worksite supervisor shall:
A permit to work, supported by an excavation certificate, has been obtained before
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work commences and that permit conditions are observed.
All personnel wear the correct personal protective equipment at all times whilst
undertaking the work.
All persons are properly supervised at all times whilst the work is taking place.
The excavation is adequately protected against possible collapse.
The excavation is properly protected, having proper regard to location, depth and
public accessibility.
The safety aspects of the excavation work are properly addressed, and that any
written excavation plan is properly followed.
7. Worker
Worker shall:
Ensure that all excavation work is carried out safely based on the written work
instructions and PTW requirements.
Ensure that all safety precautions are adhered at all times at work site.
Comply with rules and regulations related to safe excavation.
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6.0 EXCAVATION REQUIREMENTS
Unless unusual conditions are encountered, e.g. loose sand or the like, a
shallow trench may usually be excavated without being battered or supported
(see Figure 1)
The maximum angle of batter permitted, in optimum conditions for any unsupported
excavation, shall be 45 degrees from the horizontal
Dewatering is necessary if the water table is less than 0.5m from the bottom
of the intended maximum dept of the excavation (i.e more than 1.7m
depth). A dewatering plan is to be submitted to the relevant Site
Supervisor for approval in these cases.
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6.3 DEEP EXCAVATIONS
It is highly likely that dewatering will be necessary for deep foundations. Deep
dewatering may have a significant impact on the surrounding environment,
e.g. subsidence of roads, buildings, pipelines and etc.
Mechanical digging is not permitted unless the area to be excavated has been
checked by use of a cable/metal locating tool and pilot trenches have been
dug (see Section 6.10 and 6.11).
The location of any encountered services shall be clearly marked with a red
peg and the type of service (cable or pipe) identified. A record, usually a
drawing, shall be made showing the exact location of encountered services
and shall be submitted to the relevant Site Supervisor. Only after he is
satisfied that all necessary precautions have been taken shall mechanical
digging proceed.
All mechanical digging equipment shall be suitable for the area classification
of the plant and comply with permit requirements.
Prior to commencement of the work, the contractor shall be provided with all
available soil investigation reports. Requirements for any additional soil
investigation should be clearly specified in the contract.
A detailed design shall be included for the full length of the heading or tunnel.
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Figure 2 - Trench Depth between 1.5 m and 3.0 m without Shoring
The use of supports which are designed and specified on-site shall only be
allowed for (refer Appendix 5):
Where water problems have been eliminated by other means and the
limitations in (i.) and (ii.) above have not been exceeded.
All support requirements which do not fall within the specifications laid
out above shall be specially designed. This includes excavation adjacent to
sectional foundations where standard excavation is not possible.
Specialist advice shall be sought if there are any doubts as to the safety
and sufficiency of any support system which has been designed and specified
on-site.
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6.9 WRITTEN EXCAVATION PLAN
The excavation plan and attached sketches should show that consideration
has been given to the following:
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6.9.2 Preparation
The excavation plan shall show that checks have been made to locate:
The excavation plan shall show that checks have been made to ensure that
the persons who will be responsible for supervising the work at site are
competent to do so.
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services.
Obtain the necessary work permits, supported by the excavation
certificate.
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Figure 3 - Pilot trenching prior to Mechanical Excavation
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Figure 4 - Pilot trenching prior to Mechanical Excavation
Unshored excavations:
Spoil may be disposed of along the sides of the excavation, provided that the
distance to the edge of the nearest portion of the spoil heap is not less than
the final excavation depth (see Figure 1).
Shored excavations:
Spoil may be disposed of along the sides of the excavation, provided that the
distance to the edge of the nearest portion of the spoil heap is greater than 1
meter (see Figure 5).
6.12.2 Backfilling
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6.13 GAS TESTING
The gas testing programme shall form part of the excavation plan. In
circumstances where a hazardous atmosphere is found to exist, the
work shall be suspended and the excavation shall be treated as a
Confined Space
6.14 VENTILATION
All electrically operated blowers must be classified for the hazardous area in
which they are to be used.
6.15 LIGHTING
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6.16 WATER REMOVAL
Wherever surface ditches, streams etc. are incapable of draining off excess
water, trenches shall be constructed to carry the water away from the
excavation.
The trenches shall be designed to cope with the maximum rainfall which may
be expected whilst the excavation is in progress. If unexpectedly high
rainfall occurs during excavation operations, water removal by manual or
mechanical means shall be carried out.
Mud trap may need to be installed around excavation site to trap mud debris
from flowing into the public storm drain.
Where the presence of ground water may create difficult working conditions
or may endanger the stability of the sides and/or floor of the excavation, the
excavation shall be:
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Figure 5 - Trench Depth less than 3.0m with Shoring
6.17.1 Access
A safe means of access to and egress from the excavation shall be provided
for personnel and machinery.
Personnel Access
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Material and Vehicle Access
Bridges shall be installed where plant and vehicles are required to cross
excavations. All bridges shall be specifically designed and constructed by
competent engineers to ensure:
6.17.3 Barriers
Barriers and stop blocks shall be erected at a suitable distance from the
excavation to prevent:
Additionally, the edges of all excavations, where personnel may fall more
than 2 meters shall be protected by rigid barriers or, alternatively,
excavations shall be securely covered.
Non-rigid barriers may be used in areas where access for persons and
transport is not required. The materials used shall give an obvious warning
by being immediately apparent and brightly colored.
Wherever barriers are set back from the edge of the excavation, all access to
the excavation shall be confined to proper paths and roads and materials
should not be stacked in the space between the barriers and the edge of the
excavation.
6.18 CHECKLIST
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7.0 EXCAVATION PROCEDURE
7.1 PREPARATION
The Excavation Plan with its attached excavation drawings shall be approved
by approving authority that is responsible to ensure that the location has
been checked against the underground services drawings for civil,
mechanical, electrical, instrumentation, and telecommunications obstacles
and to provide the appropriate controls. The area of the proposed excavation
shall be surveyed to identify/confirm the locations of the underground
services.
The Excavation Certificate Approving Authority shall:
Ensure that the scope of work is adequately documented.
Visit the site.
Ensure the extent of excavation is adequately marked.
By reference to the drawings listed above, determine the existence of all
and any underground services, structures or foundations and where
possible mark these.
Stipulate any special precautions on the excavation plan.
Specify the requirements of emergency and rescue plan
Excavations deeper than 1.5 meters where the width is narrower than the
depth shall not be undertaken unless other alternatives have been duly
considered.
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7.2 DURING EXCAVATION
The Engineer/Supervisor in Charge shall visit the excavation site each day or
after every rain storm to check:
In addition a Gas Test shall be carried out each working day by an AGT
before the commencement of work. Additional gas tests shall be carried out
as per requirements specified in the Permit to Work.
All drawings shall be updated and marked at site to clearly reflect all
underground services, structures or foundations.
8.0 PRECAUTIONS
Ensure that:
the written excavation plan is followed at all times.
the correct personal protective equipment is being worn.
barriers are in place and are of an adequate construction.
stops for lorries and dumpers are in place to prevent them falling into
the trench.
signs and warning lights are adequate for the purpose.
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tipping areas are clear.
foot bridges and vehicle bridges are in a safe condition, supported
and with rails in place.
debris boards are in place.
safe access and egress is maintained.
the ground and water table is as assumed for the excavation plan.
pumping operations do not remove fine particles from the soil and
weaken the structure.
wedges are secure on timbering and sheet piling and supports are
safe during any compaction operations.
exhausts are positioned clear of the trench or excavation.
trench sides are clear of hazards.
the ground is not deteriorating during the work.
proper slinging arrangements have been made for the removal of
debris.
visibility and lighting is adequate.
the edges of the excavation are clear of soil and debris for a distance
equivalent to the excavation depth, or 1.0 metres in the case of shored
excavations.
work is suspended if an underground service is damaged. Broken
cables and burst pipes must be reported to the asset owner as soon
as possible to obtain isolations and repairs. All incidents must be
reported in accordance with HSE Standard.
Ensure that in deep trenches, pits or shafts, tests for oxygen
deficiency, flammable gases and toxic gases are carried out at least
once per day, before work commences, and when work has stopped
for 1 hour or longer.
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Failure Modes
In shallow and unsupported excavations ensure that the type of ground being
excavated is not liable to the failures which may occur in relatively shallow
excavations.
Ensure that unsupported or battered excavations in soft clays do not fail due
to rotation.
Ensure that unsupported or battered excavations in stiff clays do not fail due
to:
the relief of lateral restraint which allows the top of the excavation to swell
inwards
by rain or other surface water penetrating fissures at the surface and
softening the clay (earth falls (landslide) are more frequent in wet
weather).
8.1.3 Rock
Ensure that all loose rocks hanging to the excavation face are removed as
the digging proceeds.
Large volumes of heavy rock can move short distances very rapidly. Ensure
that rock excavations are supported, even for shallow excavations, if there is
any doubt over the integrity of the rock face.
Where excavation supports are designed and specified on-site, ensure that:
proper account has been taken of the ground conditions when deciding
the method of support,
the method of support complies with recognized good practice in all
details.
Where proprietary systems are used, ensure that the installation is strictly in
accordance with the manufacturers instructions.
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8.2.2 Supports Design by Specialist Engineers
8.3 ACCESS
Ensure that access to and from ladders is on firm ground and that the
ladders are:
8.4 BARRIERS
Ensure that:
barriers or stop-blocks are fitted at all locations where cranes,
dumpers, lorries, tippers etc. manoeuvre close to the edge of the
excavation.
the edges of the excavation are protected from damage during vehicle
manoeuvres.
Warning light shall be installed around the excavation site during night
hours.
Ensure that the means of escape and rescue are provided and maintained
throughout the duration of the excavation activities.
Ensure that all personnel are trained in the emergency procedures including
escape and rescue plan which shall be followed in the event of an
emergency.
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in length, an area with a radius of 100 meters from the object should be
evacuated. An area with a radius of 250 meters should be cleared for
larger objects.
Using poles and flutter tape, set up a cordon round the evacuated area
then notify management of the action taken.
Prevent access to the cordoned-off area
If the object is discovered in or near a company installation, all the
services in the area shall be isolated to minimize the effect of possible
ruptures to pipelines and vessels.
Only adequately trained and competent persons shall be permitted to work. Any person
involved in excavation work shall receive relevant training such as excavation, confine space
entry, Permit to Work system, authorized gas tester, job safety analysis and etc.
Training records for all persons who have attended courses and reached a satisfactory
standard in the test shall be kept by their employing company and are available for
verification.
For excavation training it should cover the contents of this procedure and
other safety requirements which may be applicable, the use of safety
equipment required for the job, the basic principles of working in excavation
area and safe operating methods for the types of equipments to be used.
9.2 EXPERIENCE
Inspection and audit plan shall be established for excavation activities on site.
Recommendation and findings arising from the inspection and audits shall be tracked until
closure.
OPUs/JVs management shall conduct excavation system review regularly based on the
incident, inspection, audit findings and new regulatory requirements.
Lessons learnt from excavation incidents shall be shared amongst employees, contractors
and OPUs.
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11.0 REFERENCES
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APPENDIX 1 Ground Condition and Slopes
SAFE TEMPORARY
SLOPES
GROUND TYPE FIELD TESTS AND DESCRIPTIONS
(See notes)
(Degrees from horizontal)
40/45
35/45
See (6) & (7)
1. Levels of water Full description See note 1 (d) See note 1 (d)
encountered necessary
GROUNDWATER 2. Rate of entry
3. Standing level
4. Flood conditions
THE SUGGETSED SLOPE ANGLES ARE FOR GUIDANCE PURPOSES ONLY SEE
NOTES
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NOTES ON GROUND CONDITIONS:
2. Dry site: minor or no seepage from excavated faces. Minor or no surface run off.
4. The behavior of soils is influenced by the grading, particle size, shape and
density. In mixed soils the maximum grain size of the smallest 15 percent by
weight of the grading tends to characterize the soil.
5. Normally consolidated clays are usually stronger within a few meters of ground
level due to desiccation. However, the clay crust is fissured for the same reason
(note the fissures may not be visible) and is seldom more than 4 meters deep.
Due to the fissuring, the face becomes unstable and lumps fall into the
excavation. In deeper excavations there is a risk of toe failure due to underlying
softer clay. The suggested slopes are intended to avoid danger to workers from
these risks and are offered as a guide only.
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APPENDIX 2 - Checklist for Excavation Plan
The following information will be required in order to determine the method of excavation and
the need for support. In addition, in the case of trench work in particular, what has to go into
the trench or excavation will be important. The handling of such items may well affect the form
of support that can be used. The answers to the following questions need to be considered
before any decisions can be taken.
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APPENDIX 3 - Checklist Prior to Start of Work
1. Is the person directly supervising the work, fully experienced and competent in the
support of excavations?
3. Are the necessary drawings or sketches (where on-site developed support designs
are to be used) available? Have the operatives been properly briefed and instructed
as to what is required of them?
4. Are all materials necessary available on site and in accordance with the
drawings/sketches?
5. Has all machinery to be used in the excavation been certified as fit for use and is it
suitable for the work it will be undertaking?
6. What arrangements are required with regard to site security (especially for those sites
where members of the public may enter the area)?
7. Is there adequate working space for the proposed plant and equipment to be used?
8. Is there adequate room for spoil heaps and are they positioned more than 1.5 metres
from the edge of the excavation?
9. Will bridges or gangways be needed? If so, are the materials and equipment ready?
10. Are there sufficient ladders available for access to and from the excavation?
12. Is all the appropriate personal protective equipment available for personnel?
13. Are all personnel competent to carry out this type of excavation without additional
training and/or supervision?
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APPENDIX 4 - Checklist Whilst Work is in Progress
The following list covers only the main points which need to be checked when
inspections and examinations are being carried out whilst work is in progress.
1. Is access to and from the work face sufficient and secure from danger?
2. Are all working faces secure, wedges tight and support material free from damage?
5. Are the spoil heaps being properly maintained and positioned more than 1.5 metres
from the edge of the excavation?
6. Are pipes, bricks and other materials kept well clear from the edge of the excavation so
that there is no risk of them falling into the excavation due to accidental dislodgment?
7. Is all plant and machinery kept well clear from the edge of the excavation so that there
is no risk of vibration damaging the support?
9. Are the walings and struts, or proprietary equipment, supported against falling
downward - by hangers, puncheons, lip blocks etc.?
10. Is there any risk of flammable or toxic gases entering the excavation?
11. Is there any risk of an oxygen deficient atmosphere occurring inside the excavation?
14. Have all personnel been instructed in the evacuation procedure for the excavation, and
the correct rescue procedure to follow, if someone is overcome by toxic or asphyxiating
gases.
15. Have all support materials been checked before installation in the excavation? In
particular are the correct pins provided in the trench struts?
16. Is the work adequately barriered off? Have all the relevant safety signs been posted at
entry/exit points? Is the work adequately barriered or covered and lit at night? Are
watchmen needed?
17. Are personnel wearing the proper personal protective equipment? Are any other items
of PPE required?
18. In pits, shafts and tunnels, in particular, is adequate lighting provided? Is the temporary
lighting system safe and free from damage?
19. Are gangways and bridges properly designed and constructed and in a good state of
repair? Are they the correct width? Do they have the correct guardrails and toeboards?
21. Is the support withdrawal part of the excavation plan still feasible? Are the persons
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carrying out the support withdrawal competent to carry out the work and have they
been properly instructed?
22. Where pumping is taking place, is a proper check being kept to ensure that fine material
is not being withdrawn from behind the support system?
23. Are the operatives all working in a safe and competent manner?
24. Is the excavation plan being followed? Is it working or does it require some amendment
so that the task can be performed more safely? Do you require expert assistance in
any of the tasks which are being performed?
25. DOES THE SITE HAVE THE PROPER ONGOING SUPERVISION WHICH IS
ESSENTIAL TO MAINTAIN A SAFE PLACE OF WORK?
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APPENDIX 5 Support and Shoring of Excavation
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