UROP PROJECT

MANAGEMENT FAILURES IN ACCIDENTS AT WORK SITE

Focus: Scaffolds

By S.R.SHREENIVAS

Matric Number: U059898E

Supervisor: Prof DAVID CHUA

Abstract:

This paper briefly addresses the important stringent selection parameters that construction
contractors need to take into consideration before employing scaffolding company.
Secondly the paper also highlights few commonly used scaffolds and the necessary
standards and requirements prior to installation at sites. Finally the type of scaffold to be
used in the future and its advantages over the present type of scaffolds has also been
explored.

Introduction:

The scaffolding industry has evolved - not much in terms of technological tools, but
rather on the legislations governing its construction & usage. Globally, we have seen
governing bodies and statutory boards revising and imposing new legislations to ensure
higher safety governance on scaffolds. One of the major international changes recently is
the withdrawal of the long-serving BS5973:1993 and the introduction of the EN 12811-1
- that also covers system scaffold.

Nearer to home, our construction industry is on a rise here in Singapore and with number
of buildings coming up in the next decade or so being predominantly sky scrappers, its
imperative from Construction Company’s point of view to make sure their site is free
from accidents /casualties. Majority of accidents at site arises due to fall of workers,
subcontractors, visitors from “heights”. In Singapore, about 38% & 26% of falling from
height accidents in the shipbuilding & construction industries respectively involved
scaffolding & access. One of the reasons could be attributed due to poor quality and
supervision of scaffolds at sites. The scaffolds are to be installed, maintained, inspected
and dismantled in a safe way to prevent these sorts of incidents from taking place.
Selection Criteria for Selecting Scaffolding Firm:

It is estimated that employers globally lose an approximate 90 million in lost work days
because they are not taking the necessary measure to prevent injuries and death. In the
UK alone, an estimated 65% of the construction industry – or the equivalent of 2.3
million workers – regularly use scaffolding so that employees can access difficult-to-
reach areas of the building. Around 50 people have died each year in the UK because of
scaffolds that collapsed and over 4,500 are injured due to faulty or poorly-built scaffolds.
Construction workers are twice as likely as workers in the other industries to suffer from
work-related injuries and falling from height – still one of the biggest contributors to
accidents globally. Further studies from scaffold-related accidents claimed that 72% of
such accidents are mainly due to either by planking giving way, or by an employee
slipping on platforms or being struck by a falling object.

In Singapore, about 38% & 26% of falling from height accidents in the shipbuilding &
construction industries respectively involved scaffolding & access. In 2004, the Ministry
of Manpower rolled off the first of many work-based programs called the PROBE
(Program-based Engagement) and targeted the scaffold industry for improvement.
Following this PROBE program – the introduction of the recently legislated Scaffold
Regulations (2004) took off - shifting the ownership and liability towards safety back to
the industry. Instead of providing a set of laws & guidelines for the industry to comply –
the new act ensures that the industry put their act together and led the way to attain higher
safety performance and improvement. People who are indirectly involved with the work
such as directors & managers are now liable to be taken to task by the law if they are
deemed to have failed in their part to ensure the Work, Health & Safety is in place before
work commences and when work is in progress.

Companies are to be careful in selecting scaffolding firms and to make the selection an
accurate and error free process they need to have stringent selection criteria in place. First
and foremost the scaffolding company must be an Approved Scaffold Contractor (ASC) –
accredited by MOM (Ministry of Manpower) Singapore. It’s also important to study on
firms previous projects. The best way of checking on a firm’s reputation is to ask those
who have used them earlier. Any reputed scaffolding firm would be able to provide list of
last few projects that they have done and its vital to ask previous users about the firms
safety features, their on-time installation, quality of the equipment used, any damage they
had incurred while using the scaffolds and finally ask them if they would employ the
same scaffold firm again for their future projects. These analyses would give companies
clear indication and clarity when they are choosing scaffolding firms. All these
information should be asked to be submitted together with the Price Proposal i.e. to have
two parts in a typical scaffold bid submission – Commercial & Technical Submission.

Secondly it’s important to check the quality of scaffolds. Given that companies are going
to rely on the scaffold to give their sub-contractors, visitors, and other officials to give a
safe place to work with it’s imperative to check the quality of the scaffold used. Most of
the scaffolding firms have gone down the road of having their systems checked by
authorized competent and qualified third party auditors in order to gain the ISO:
9001:2000 quality accreditation. Apart from ISO it’s also important to find out if they are
complaint to CP14 (Code of practice). The code provides basic requirements to be met
for good quality scaffolds.

Low-costs scaffold suppliers can easily be found in the market but the onus is on the
hiring company / contractor / developer to carefully select scaffold contractors which can
provide quality & safe scaffolds. The result of getting lowly priced scaffolding quotes can
be attributed to the following:

1. Materials – not complying to Code of Practices, poor quality which may lead to
high rate of failure
2. Storage & Transport – low costs
3. Labor – unskilled, unqualified, un-motivated
The result of not qualifying/assessing a scaffold contractor prior to contract awards could
be dire. Here are some examples:

Scaffold Accidents around the World

Fig 1(a),1(b): Philippines Accident

 SCAFFOLD COMPONENTS NOT MANUFACTURED TO A RECOGNIZED
STANDARD

Poor bolt
manufacture
Sharpe angle
leading to
stress
fracture
No Centre dividing
plate

Slip Test >10.6kN

Failure @ 9.7kN

Distorted
Rivet Bolt
Damage

Fractured
bolt

Fig 2: Sub-standard boards

Getting a good written quote from the scaffolding firm is another important requirement.
The quote should necessarily contain the clearly marked diagrams with dimensions, the
number of lifts of scaffolds that are required to be boarded, the period of hire(important
to obtain a hand mover certificate),any alternations for follow on trades (bricks, roofers,
glaziers), the period of time in which it will take to install and remove structures, the
number of ladders needed for each elevation and most important is that users must make
sure scaffolding firms clearly state the installations process, the scaffold materials and the
handed-over ready –for-use scaffold structure complies with Singapore occupational
health and safety board. Any reputable firm would want to visit the site first, have detail
drawings of the structures before committing to final quotations.

A typical scaffold bid submission should be structured as follows:

Technical Submission Commercial Submission
• Safety Management System • Preliminaries costs - Is the costs
• Safety & Quality Plan that Contractor has drawn up to
• Method Statement support in carrying out the project
• Risk Assessment efficiently. Include costs of site

• Approved Scaffold Contractor management, administrative, safety

Certificate awards & promotion, supervision,

• Material Test Certificates other indirect personnel, equipment

• Manufacturer’s Mill Certificate & machineries, transportation,

temporary facilities & consumables
• Organization chart
that will be expended during
• Safety Statistics/performance
execution of the works throughout
• Past project experience
the whole duration of the contract.
• Workforce data – no. of staff &
• Unit Rates or total lump sum costs
workers available & their
of scaffolding works.
responsibilities/skill levels
• Unit rates for labor & supervision,
• Organization charts
machineries & equipment
• Scaffolding Technical Data
• Project Execution Plan
Thirdly it’s extremely crucial to ask for proof of competency for the scaffolders that
would do the work. Any competent scaffolder should have sat for scaffold trade test to be
called scaffold erectors. The person supervising the scaffold erection or managers should
necessarily have had some sort of formal health and safety training and minimum of two
years of experience in relevant fields to be called a scaffold supervisor. All these have to
be taken into consideration before one employs a scaffolding firm.

Another question arises as to how much one needs to pay to employ a reputed scaffolding
firm. This is were many construction companies go wrong. They usually get four to five
quotes and go for the cheapest one. This is usually a big mistake (See below table to
illustrate this point). It is important to remember how important the scaffold is to the
project. Generally price of scaffolds reflects the quality of the materials used, the
competency of the scaffolders used and the levels of after sales service. Sometime even
though the quality, type and the design of the scaffold is good it is a lot easier and
cheaper for scaffolding firm to carry out a sub-standard installation, using untrained,
uninsured staff with inferior work practices and equipment; this implies that the quotes
are bit low in spite of the material proposed being of good quality. These points have to
be closely monitored and compared to other quotes. If there is huge variation with no
apparent reason it is important to critically analyze the reason for these differences. All
these would cumulate into selecting good quality scaffolding firm.

Low cost Disadvantage

1. Low price tender - Leads to poor quality
- High rate of equipment failure
- Equipment related accidents
- Disorganized storage of materials
- Low equipment utilization
- Poor equipment maintenance
Finally before installation companies should be possessing the suitable method statement
(MS) and the Risk assessment (RS) of the scaffolder. A method statement is a simple
point by point picture of how the scaffolder intends to install ,maintain and dismantle the
scaffold and Risk assessment is a concise record of potential hazards(something with
potential to cause harm),the risk(the odds/chances of harm) and the control measure put
in place to minimize the potential risk. Each and every task must have a MS & RA to
accompany it and it must be specific to that particular scaffold operation. Any scaffold
firm with correct safety record should be able to provide the documents.

Keeping in mind some of these procedure/check list mentioned above would go a long
way in making sure scaffolds do not contribute to casualties at work sites.

Types of Scaffolds:

There are different varieties/types of scaffolds used in Singapore with each type having a
unique design and features compared to its counterparts.

In general there are three types of scaffolds namely frame, tubular and modular. The
frame scaffolds is commonly used locally, however for buildings which do not have
straight profile tubular, modular scaffolds are more suitable.

Tubular scaffolds are the most commonly used type and is typically seen in most of the
construction sites in and around the country.
 Fig 3. Tubular Scaffold

Typical independent scaffold as shown in fig 1 clearly illustrates the different parts that
make up a tubular scaffold. Most of the tubular scaffolds used now days is made of
Galvanized Steel. The scaffold supervisors shall ensure scaffold is erected, installed, re-
positioned, altered or dismantled in accordance with regulations. Scaffold erectors
(persons undergone training approved by MOM) shall be provided with safety harness
with shock absorbing devices when carrying out any work on the scaffold (includes other
types of scaffolds as well). Tubular scaffolds seen commonly at construction sites do
have certain design restrictions / limitations which when exceeded/reduced would lead to
violating norms as stated in the Scaffold Regulations (2004). Some examples of the basic
requirements for installing a tubular scaffold would be highlighted in the course of the
study.

Firstly standards are to be placed as close as possible to each other and not to exceed
2.5m. Spigots; joint pins or sleeves must be used for connecting of standards. Spigots
,joint pins should engage in the ends of the standards by at least 70mm and sleeves
should cover the ends of the standards by at least 70mm. Ledgers should not run
longitudinally along the face of the scaffold and should be spaced at vertical intervals of
not more than 2 meters. Distance between workplatforms is not to exceed by 4m.
Professional engineer (PE) is to design if tools and materials on the platform exceed
25kgf/sq.m. The work platform has to be extended beyond the end of the wall by at least
600mm. Similarly, other requirements are to be followed prior to installation. The
scaffold supervisors would be responsible for proper adherence to the Scaffold
Regulations (2004) for installation.

Scaffolds made of timber (Bintangor) were also used earlier but with the advent of
materials and the ability of the materials to be tailored to suite particular applications has
lead to use of aluminum, steel and other man processed material for scaffolds nowadays.
The cost of tubular scaffolds is far less compared to other types. Tubular scaffolds do
have its share of disadvantages in form of storages.

Secondly Cup lock scaffolds are also used in Singapore but not as widely used as frame
scaffolds.

Fig 4 a :Cuplock (enlarged) Fig 4 b:Cuplock scaffold

The main advantage of Cup locks is that, they can be erected for straight, curved and
circular configuration for both access and support and for independent and mobile
towers. Cup locks are easy to maintain and highly resistant to damage.

The Cup locks scaffolds are erected 75% faster than traditional scaffoldings. Moreover
due to its modular construction cup locks require less space for storage unlike the
traditional frame scaffolds. The success of cup locks lay in the node point or fastening
method. The four horizontal are fastened at one time making a very rigid connection. The
horizontal bear directly on the verticals are firmly clamped by the action of the cup.
Cuplock systems are versatile scaffolding systems, which are used for various forms of
access and support structures and are used in building and construction industries. Easily
and quickly erected and disassembled with just a hammer needed, it reduces labor by
almost 80% in comparison with tube and clamp scaffolding .Reasonable and simple
structure and has high structure strength makes cup lock scaffolds quite reliable. The cost
of these types of scaffolds is quite high compared to the framed ones.

Some of the common type of scaffolds explained above typically is used for constructing
buildings of uniform profile (linear). With improvement in material properties and
technology architects are trying out innovative designs for the structures. There is greater
need for scaffolds to compliment the same for making the structures/buildings of
irregular profile a reality.

Scaffold to be in demand and to be widely used in future:

Having spoken to some of the architects and scaffolding contractors during the course of
the project I found out that scaffolds that were manufactured by German Company
named Layher all round scaffolding were gaining popularity in terms of materials it uses,
compatibility, durability, flexibility, ability to be used for constructing structures of
irregular profiles ,and safety.
 Fig 5: Ingenious connector technology (8 connections in one plane, automatic right-angles
and flexible angle selection, self-locking during assembly, material-saving)

Layher All-round scaffolding has become established on the market as a synonym for
modular scaffolding. With its unique technology, the All-round¨ connector has
superseded conventional scaffolding connection techniques. The original offers an
unbeatable variety of uses: at every construction site, in industry, chemical plants, power
stations, shipyards and for events. As scaffolding for working, protection, facades or for
support, as internal or birdcage scaffolding, or as rolling towers. All round equipment
caters flexibly for all requirements, even with very difficult layouts and architecture
styles and with heightened safety requirements.

Examples of some of the Layher scaffolds used in Germany for constructing structures of
irregular profiles .Layher scaffolds are gaining popularity in Singapore.
Fig: 6 a: The southeast tower of the Ulm cathedral was scaffold with Layher All-round
material. At the inside of the helm roof there is also a scaffold, which was coupled with
the outside scaffold. Thus one reaches better stability without using anchors.

Fig 6 b: Mobile All-round Scaffolding at the Rennsteig tunnel, which is Germany's longest
road tunnel. The All-round Scaffolding runs on rails and is used to fix the armoring.

Layher System – Advantage & Disadvantage

Advantage Disadvantage

- Quick & easy to erect - High capital cost

- Lower skills required - Limited range of suppliers

- Fewer small components to lose - A wide range of components are

required

- Difficult to transport (as compared

to tubular system)

- Ledgers & standards lack continuity

- Difficult to use in congested areas

 - Expensive to maintain & repair

Conclusion

Good scaffold practice is a three-pronged responsibility to be undertaken by the

following group of people:
1. The Customers
2. The Scaffold Contractor
3. The User

The Customer
• Select a competent scaffolding contractor
• Induct scaffolding work force in site safety procedures
• Specify the main purpose for the scaffold and follow on activities
• Identify potential hazards
• Identify vulnerable plant/instruments above & below ground
• Ensure that the foundations for the scaffold are adequate
• Agree the type and frequency of scaffold ties
• Provide adequate storage area for materials
• Provide good access for delivery/collection of materials
• Ensure the integrity of the scaffold during it’s period of use
• They should prevent , as far as possible, access to the scaffold by unauthorized
personnel

The Scaffold Contractor

• Workforce should be trained, competent and experienced
• Consider the purpose for which the scaffold is to be used and check for:
- scaffold height to be built
- number of working platforms to be provided
- potential wind loads
- type & position of ties to be used
 - check if a Professional Engineer design is required
• Confirm that the foundations for the scaffold are adequate
• Carry out the erection/modification/dismantling operations using safe methods of
work
• Ensure that the scaffold structure is safe and secure during all phases of erection and
dismantling
• They should inspect the scaffold on a weekly basis and after any weather or event
which could have caused damage to the structure

The User
• Users of scaffolding should ensure that It is:
- Properly Constructed
- Suitable for it’s Purpose
- Maintained in good condition

• User should ensure that the scaffold foundations, boarded platforms, ties or bracings
are not interfered with by unqualified persons
• Users of the Scaffold should be aware of the loading capacity of the scaffold
• They should not overload any part of the scaffold by concentrating stored materials
at one point

The paper had looked into precautionary measures before employing a scaffolding firm
and also looked into common scaffold types used in Singapore. The paper also explored
the scaffold manufactured by Layher gaining popularity and to be used widely years to
come. The project has really helped me to look into safety issues at constructing sites and
being a mechanical engineering graduate the project was really a good learning
experience for me to have an understanding of subject relating to civil engineering
discipline.
I am thankful to NUS and Prof Chua for providing me with an opportunity to do research
on discipline which was completely new to me and after having completed the project I
am confident I was able to find out issues leading to accidents at worksites and was able
to provide inputs to minimize the same.