Labour Welfare II: Industrial Health and Hygiene, Industrial Accidents and Safety, and Occupational Diseases

The second chapter on Unit IX takes the three items of the Labour Welfare heading that concern the worker's body: industrial health and hygiene, industrial accidents and safety, and occupational diseases. It sets out the joint ILO/WHO idea of occupational health, the hazards industrial hygiene measures and the hierarchy of controls, the theories of accident causation from Heinrich's dominoes to Reason's Swiss cheese, the frequency and severity rates by which accidents are measured (worked with numbers), the organisation of safety at the workplace and in national policy, and the occupational diseases — the pneumoconioses, metal poisonings, occupational cancers and others — that the Factories Act makes notifiable and the compensation law treats as injury.

1. Industrial health and occupational health services

The Joint ILO/WHO Committee on Occupational Health (1950, revised 1995) defined the aims of occupational health as the promotion and maintenance of the highest degree of physical, mental and social well-being of workers in all occupations; the prevention among workers of departures from health caused by their working conditions; the protection of workers in their employment from risks resulting from factors adverse to health; and the placing and maintenance of the worker in an occupational environment adapted to his physiological and psychological capabilities — in short, the adaptation of work to man and of each man to his job. Occupational health services put this into practice through pre-employment and periodic medical examinations, the surveillance of the work environment and of workers' health, first aid and emergency care, health education, advice on ergonomics and the placement of workers with disabilities, and records. In India the Factories Act's hazardous-process chapter requires medical examination of workers in hazardous processes and health records, section 87 empowers rules for dangerous operations, the ESI scheme provides medical care, and the Directorate General, Factory Advice Service and Labour Institutes (DGFASLI) and its regional labour institutes study occupational health and train factory medical officers.

2. Industrial hygiene and the control of hazards

Industrial (occupational) hygiene is the science and art devoted to the anticipation, recognition, evaluation and control of environmental factors or stresses arising in or from the workplace that may cause sickness, impaired health or significant discomfort among workers. Hazards are grouped as physical (noise, vibration, heat and cold, ionising and non-ionising radiation, poor lighting, abnormal pressure), chemical (dusts, fumes, gases, vapours, mists and liquids, entering by inhalation, skin absorption or ingestion), biological (bacteria, viruses, fungi and parasites, as among health-care, agricultural and sewage workers), ergonomic (awkward postures, repetitive motion, manual lifting) and psychosocial (shift work, workload, harassment and stress). Exposure is evaluated by measuring concentrations and comparing them with exposure limits — the permissible limits of exposure in the Second Schedule of the Factories Act, or threshold limit values of the kind published by the American Conference of Governmental Industrial Hygienists.

Hierarchy of controls (most to least effective)Example
1. EliminationStop using the hazardous process or substance altogether
2. SubstitutionReplace a toxic solvent with a less toxic one; replace asbestos with safer fibres
3. Engineering controlsEnclosure, isolation, local exhaust ventilation, wet methods for dust, machine guarding
4. Administrative controlsJob rotation to limit exposure, permit-to-work systems, training, warning signs, housekeeping
5. Personal protective equipmentRespirators, ear protection, gloves, goggles, helmets — the last line of defence

3. Industrial accidents: causes and measurement

An industrial accident is an unplanned, unexpected event arising out of and in the course of employment that causes or could cause injury or damage. The Factories Act requires notice of any accident that causes death, or bodily injury that prevents the injured person from working for forty-eight hours or more immediately following it (section 88), and of dangerous occurrences whether or not anyone is hurt (section 88A). H. W. Heinrich's Industrial Accident Prevention (1931) framed the classic account. His domino theory arranged five factors in sequence — ancestry and social environment, fault of the person, an unsafe act or unsafe condition, the accident, and the injury — so that removing the middle domino (the unsafe act or condition) prevents the injury. From insurance records he concluded that 88 per cent of accidents are caused by unsafe acts, 10 per cent by unsafe conditions and 2 per cent are unpreventable, and that for every major injury there are 29 minor injuries and 300 no-injury accidents (the 1:29:300 ratio). Frank Bird's study of 1969 revised the ratio to 1 serious injury, 10 minor injuries, 30 property-damage accidents and 600 near misses. Accident-proneness theory (Greenwood and Woods, 1919) held that some individuals have more accidents than chance would predict. James Reason's "Swiss cheese" model (1990) sees accidents as the alignment of holes in successive layers of defence — latent organisational failures as well as the active errors of individuals — which shifts attention from blaming the worker to fixing the system.

Accidents are measured by rates that allow comparison between establishments and years. The Indian Standard (IS 3786) uses a base of one million man-hours worked. The frequency rate is the number of lost-time injuries per million man-hours worked: frequency rate = (number of lost-time injuries × 1,000,000) ÷ man-hours worked. The severity rate is the number of man-days lost per million man-hours worked: severity rate = (man-days lost × 1,000,000) ÷ man-hours worked. The incidence rate is the number of injuries per thousand workers employed. A factory that works 6,00,000 man-hours in a year and has 12 lost-time injuries causing 360 man-days lost has a frequency rate of 20 and a severity rate of 600. (American practice under OSHA uses a base of 200,000 hours, which gives smaller numbers for the same experience.)

4. Organising safety

  • Management commitment and a written safety policy: the Factories Act (section 7A) requires the occupier to prepare a written statement of his general policy on the health and safety of workers.
  • Safety organisation: safety officers (1,000 or more workers under section 40B), safety committees with equal representation of workers (section 41G for hazardous processes), and supervisors trained in safety.
  • Hazard identification and risk assessment, job safety analysis, permit-to-work systems for hot work and confined spaces, safety audits and inspections, and investigation of accidents and near misses.
  • Training, safety education, suggestion schemes and safety competitions; the National Safety Council of India (set up in 1966, Mumbai) observes National Safety Day on 4 March, its foundation day.
  • National policy and standards: the National Policy on Safety, Health and Environment at Workplace (2009); management-system standards such as ISO 45001 (2018); ILO Conventions 155 and 187, which India has not ratified; and the OSH Code's National Occupational Safety and Health Advisory Board.

5. Occupational diseases

An occupational disease is one contracted as a result of exposure to risk factors arising from work. It usually develops slowly, after long exposure, and is often recognised only when it is advanced, which is why periodic medical examination matters. Section 89 of the Factories Act requires medical practitioners and managers to notify the diseases listed in its Third Schedule, and the Employees' Compensation Act (Schedule III) treats the listed occupational diseases contracted in the listed employments as injuries by accident, so that they are compensated. The pneumoconioses — lung diseases caused by inhaling dust — are the most important group in India. Percivall Pott's description in 1775 of scrotal cancer among London chimney sweeps, caused by soot, is usually taken as the first recorded occupational cancer.

DiseaseCauseTypical occupations
SilicosisFree crystalline silica dustMining, quarrying, stone crushing and cutting, sandblasting, foundries, slate-pencil making, glass and ceramics
Asbestosis (and mesothelioma)Asbestos fibresAsbestos mining and processing, insulation, brake linings, shipbreaking
Anthracosis (coal workers' pneumoconiosis)Coal dustCoal mining
ByssinosisCotton, flax or hemp dust; chest tightness worst on the first day of the working week ("Monday fever")Cotton textile mills, ginning
BagassosisMouldy sugarcane bagasseSugar mills, paper and board from bagasse
SiderosisIron oxide dustWelding, iron-ore mining, grinding
Farmer's lungSpores in mouldy hay and grainAgriculture, grain storage
Lead poisoning (plumbism)Lead dust and fumes: anaemia, colic, wrist drop, a blue line on the gumsBattery manufacture and recycling, smelting, paints, printing
Mercury poisoningMercury vapour and compounds: tremor, erethism, gum diseaseChlor-alkali plants, thermometers, gold extraction
Occupational cancersBenzene (leukaemia), vinyl chloride (liver), aromatic amines (bladder), soot and tar (skin)Chemicals, dyes, petroleum, rubber
Noise-induced hearing loss; decompression sickness; occupational dermatitisProlonged loud noise; rapid decompression; irritants and allergensTextile weaving and engineering; caisson and diving work; cement, chemicals, leather
⚠️ Match the dust to the disease
Byssinosis is cotton, bagassosis is bagasse, anthracosis is coal, siderosis is iron and silicosis is silica. A question that pairs byssinosis with sugar mills or bagassosis with textiles has swapped the two plant dusts.

Key takeaways

  • Occupational health (joint ILO/WHO, 1950, revised 1995): the highest physical, mental and social well-being of workers and the adaptation of work to man and man to his job; services include pre-employment and periodic examinations, surveillance, first aid and health education.
  • Industrial hygiene: anticipation, recognition, evaluation and control of physical, chemical, biological, ergonomic and psychosocial hazards; hierarchy of controls from elimination and substitution through engineering and administrative controls to PPE.
  • Accidents: notice of injuries preventing work for 48 hours (s.88); Heinrich (1931): domino theory, 88:10:2 and 1:29:300; Bird (1969): 1:10:30:600; accident proneness (1919); Reason's Swiss cheese (1990).
  • Frequency rate = lost-time injuries × 10⁶ ÷ man-hours; severity rate = man-days lost × 10⁶ ÷ man-hours (IS 3786); safety policy (s.7A), safety officers at 1,000 (s.40B), safety committees (s.41G), the National Safety Council (1966; 4 March), the 2009 national policy, ISO 45001.
  • Occupational diseases: notifiable under s.89 (Third Schedule) and compensable under the Employees' Compensation Act's Schedule III; silicosis (silica), asbestosis (asbestos), anthracosis (coal), byssinosis (cotton), bagassosis (bagasse), siderosis (iron), lead and mercury poisoning, occupational cancers (Pott, 1775).

Practice questions (10)

Attempt each one before opening the answer. Every explanation names the tempting wrong option as well as the right one, because that is where marks are lost.

  1. Byssinosis is an occupational disease caused by

    1. sugarcane bagasse
    2. cotton dust
    3. coal dust
    4. silica dust
    Show answer

    Answer: B — cotton dust

    Byssinosis afflicts workers in cotton, flax and hemp processing, with chest tightness typically worst on the first working day of the week. Bagasse causes bagassosis, coal dust anthracosis and silica silicosis.
  2. Heinrich's accident ratio of 1:29:300 relates

    1. unsafe acts to unsafe conditions to unpreventable causes
    2. deaths to injuries to near misses
    3. major injuries to minor injuries to no-injury accidents
    4. serious injuries to property damage to near misses
    Show answer

    Answer: C — major injuries to minor injuries to no-injury accidents

    For every major injury Heinrich estimated 29 minor injuries and 300 accidents causing no injury. His other ratio, 88:10:2, splits causes into unsafe acts, unsafe conditions and the unpreventable; Bird's 1:10:30:600 adds property damage and near misses.
  3. Under the hierarchy of controls, which measure is regarded as the least effective and a last line of defence?

    1. Personal protective equipment
    2. Elimination of the hazardous process
    3. Substitution of a less hazardous substance
    4. Local exhaust ventilation
    Show answer

    Answer: A — Personal protective equipment

    PPE protects only the wearer, depends on correct and constant use, and leaves the hazard in place, so it comes last. Elimination and substitution remove the hazard, and engineering controls such as exhaust ventilation contain it at source.
  4. James Reason's "Swiss cheese" model explains accidents chiefly as

    1. the fault of the worker's ancestry and social environment
    2. the result of a few accident-prone individuals
    3. the alignment of weaknesses in successive layers of organisational defence
    4. a fixed ratio of minor to major injuries
    Show answer

    Answer: C — the alignment of weaknesses in successive layers of organisational defence

    Reason (1990) treats each defence — design, procedures, supervision, training — as a slice with holes; an accident happens when holes in several slices line up, combining latent organisational failures with active errors. Accident-proneness and Heinrich's ancestry domino are older, person-centred accounts.
  5. Which of these are pneumoconioses (lung diseases caused by inhaling dust)? Select all that apply.

    1. Plumbism
    2. Decompression sickness
    3. Silicosis
    4. Asbestosis
    Show answer

    Answer: C — Silicosis; D — Asbestosis

    Silicosis and asbestosis are pneumoconioses, fibrotic lung diseases from inhaled mineral dust (so are anthracosis and siderosis). Plumbism is systemic lead poisoning, and decompression sickness results from rapid pressure change in caisson and diving work.
  6. Assertion (A): The Factories Act requires notice of an accident that prevents the injured worker from working for forty-eight hours or more. Reason (R): Section 89 of the Factories Act requires notice of the occupational diseases listed in its Third Schedule.

    1. Both A and R are true, and R is the correct explanation of A
    2. Both A and R are true, but R is not the correct explanation of A
    3. A is true, but R is false
    4. A is false, but R is true
    Show answer

    Answer: B — Both A and R are true, but R is not the correct explanation of A

    Both statements are true, but R does not explain A. Section 88 requires notice of accidents causing death or disabling injury of forty-eight hours or more; section 89, a separate provision, requires notice of listed occupational diseases. One concerns accidents, the other diseases.
  7. Assertion (A): In Heinrich's domino sequence, removing the unsafe act or unsafe condition prevents the injury. Reason (R): Heinrich attributed the great majority of industrial accidents to unsafe conditions rather than unsafe acts.

    1. Both A and R are true, and R is the correct explanation of A
    2. Both A and R are true, but R is not the correct explanation of A
    3. A is true, but R is false
    4. A is false, but R is true
    Show answer

    Answer: C — A is true, but R is false

    A is true: the unsafe act or condition is the central domino, whose removal breaks the chain before accident and injury. R is false: Heinrich attributed 88 per cent of accidents to unsafe acts, 10 per cent to unsafe conditions and 2 per cent to unpreventable causes.
  8. A factory worked 8,00,000 man-hours in a year and had 16 lost-time injuries. What is its frequency rate per million man-hours? Type the number.

    Numerical answer — type the value.

    Show answer

    Answer: 20

    Frequency rate = injuries × 1,000,000 ÷ man-hours = 16 × 1,000,000 ÷ 800,000 = 20. It means twenty lost-time injuries for every million hours worked, whatever the size of the factory.
  9. The same factory (8,00,000 man-hours) lost 480 man-days through those injuries. What is its severity rate per million man-hours? Type the number.

    Numerical answer — type the value.

    Show answer

    Answer: 600

    Severity rate = man-days lost × 1,000,000 ÷ man-hours = 480 × 1,000,000 ÷ 800,000 = 600. Frequency measures how often injuries occur; severity measures how much working time they cost.
  10. In which year did H. W. Heinrich publish Industrial Accident Prevention? Type the year.

    Numerical answer — type the value.

    Show answer

    Answer: 1931

    Heinrich published Industrial Accident Prevention: A Scientific Approach in 1931, setting out the domino theory and the 88:10:2 and 1:29:300 ratios. Frank Bird revised the injury ratio in 1969.