Safety code for the erection of Structural Steelwork
1974 Edition

Overview of IS 7205 Scope and Critical Requirements

Scope: This standard provides safety instructions specifically for the erection of steel structures, focusing particularly on bridge girders. It also incorporates references to Indian Railway standards (Serial No. B2-63) concerning erection and riveting processes.

Important Provisions:

• Emergency Jointing (Clause 6.1.5.3): In urgent situations such as impending floods before riveting is complete, joints must be temporarily secured by:
  • Occupying 40% of rivet holes with cylindrical drifts
  • Filling an equal number with fully tightened service bolts

Notes:

• The code prioritizes safe erection techniques for steel structures.
• It mainly addresses bridge girder erection and associated riveting tasks.
• For full details, contact BIS offices such as Manak Bhavan, New Delhi.

Emergency Jointing Summary Table

For comprehensive design formulas or erection methods, refer to the complete IS 7205 text or Indian Railway Standard B2-63.

IS 7205 - Organizational Safety in Steel Erection

The standard emphasizes organizational and procedural safety measures during steel erection but does not specify explicit formulas or tables under safety management.

Core Elements of Safety Organization:

• Assignment of Safety Roles: Clearly designate safety responsibilities among supervisors and workforce.
• Safety Training: Conduct ongoing education and awareness sessions for all personnel.
• Personal Protective Equipment (PPE): Mandatory use of helmets, gloves, harnesses.
• Site Safety Controls:
  • Barricade hazardous zones effectively.
  • Maintain safe entry and exit paths.
  • Establish emergency response plans.
• Inspection and Upkeep: Regular examination of lifting gear, scaffolding, and tools.
• Communication Protocols: Implement precise signaling and coordination during lifts and assembly.

Typical Safety Parameters (General Engineering Practice):

flowchart TD
    A[Safety Management] --> B[Define Safety Roles]
    A --> C[Provide Training]
    A --> D[Supply PPE]
    A --> E[Implement Site Safety]
    A --> F[Inspect Equipment]
    A --> G[Plan Emergencies]

For detailed guidelines, consult the full IS 7205 document and related standards like IS 4138 (scaffolding) and IS 5216 (lifting appliances).

IS 7205: General Safety Provisions for Structural Steel Erection

Essential Points:

• Purpose: To ensure safety during steel erection and prevent accidents.
• Safety Roles: Appointment of a designated safety officer with clear duties.
• Personal Protective Equipment: Use of helmets, gloves, safety belts, and boots is compulsory.
• Access and Working Platforms: Platforms must be stable with guardrails and toe-boards.
• Lifting Operations: Employ certified cranes and slings within rated capacities.
• Fall Protection: Safety nets or harnesses are required when working above 2 meters.
• Fire Safety: Adequate fire extinguishers and emergency exits must be available.

Typical Safety Standards (General Practice):

Safety Factor Formula for Lifting Gear:

[ \text{Safety Factor} = \frac{\text{Breaking Load}}{\text{Working Load}} \geq 5 ]

flowchart TD
    A[Safety Management] --> B[Designated Officer]
    A --> C[PPE Usage]
    A --> D[Stable Access & Platforms]
    A --> E[Lifting Operations]
    A --> F[Fall Arrest Systems]
    A --> G[Fire Precautions]

Summary: IS 7205 advocates a comprehensive safety framework including organization, PPE, secure access, proper lifting, fall protection, and fire safety to ensure accident-free steel erection.

IS 7205 - Observance of Statutory Safety Regulations

Highlights of Clause 4.1:

• Legal Compliance: All applicable local, state, and national laws must be strictly followed in addition to IS 7205.
• This code supplements but does not supersede legal safety and construction regulations.

Common Statutory Requirements:

• Building codes and municipal bylaws.
• Worker safety laws such as The Factories Act.
• Environmental and fire safety regulations.
• Workmen’s compensation and insurance mandates.

General Safety Code Elements:

• Use of PPE.
• Safe scaffolding and access.
• Load handling and crane operation standards.
• Fall prevention measures.
• Emergency protocols and first aid provisions.

Compliance Summary Table:

flowchart LR
    A[Legal Safety Regulations] --> B[IS 7205 Compliance]
    B --> C[Safety Code Enforcement]
    C --> D[Safe Steel Erection]

Conclusion: Legal requirements must be prioritized first, followed by adherence to IS 7205 and safety codes for comprehensive compliance.

IS 7205 stresses adherence to statutory safety laws to safeguard personnel involved in steel erection but does not include explicit formulas or tables on this subject.

Important Worker Safety Considerations:

• Clause 4.1: Compliance with all relevant legal safety requirements alongside this code.
• Use of PPE such as helmets, harnesses, gloves, and boots.
• Ensure safe access and exit via ladders, scaffolds, and guardrails.
• Implement fall protection systems including safety nets and lifelines.
• Maintain clear supervision and communication during erection operations.
• Conduct thorough risk assessments and deliver appropriate training.

Typical Safety Specifications (Industry Practice):

flowchart TD
    A[Start Erection Activities] --> B{Safety Measures}
    B --> C[PPE Compliance]
    B --> D[Fall Protection]
    B --> E[Safe Access and Egress]
    B --> F[Training and Supervision]
    C --> G[Helmets and Harnesses]
    D --> H[Safety Nets and Lifelines]
    E --> I[Ladders and Guardrails]
    F --> J[Risk Assessment]

Summary: IS 7205 requires legal safety compliance for personnel, supplemented by practical measures such as PPE, fall prevention, safe access, and training.

IS 7205: Ensuring Structural Safety While Erecting Steelwork

The standard underlines minimizing hazards throughout steel erection, focusing on safety principles rather than detailed calculations.

Key Safety Measures:

• Hazard Identification: Perform risk assessments prior to erection.
• Load Management: Use lifting devices within rated capacities and verify weights.
• Temporary Stability: Provide sufficient bracing and anchorage to prevent structural collapse.
• Worker Safety: Ensure PPE usage, install safety nets and guardrails.
• Communication: Maintain ongoing coordination between workers and supervisors.

Considerations:

• Temporary bracing must counter wind and erection forces, typically designed for lateral wind pressures up to 0.5 kN/m².
• Safe Working Loads (SWL) of cranes and hoists should follow manufacturer data.
• Erection sequence must be planned to maintain stability.

Safety Checks Summary Table:

flowchart TD
    A[Planning and Risk Assessment] --> B[Equipment Inspection]
    B --> C[Safe Lifting and Handling]
    C --> D[Temporary Bracing and Stability]
    D --> E[Supervision and Communication]
    E --> F[Personnel Safety]

Summary: IS 7205 promotes a comprehensive safety approach combining equipment checks, temporary structure stability, PPE, and teamwork to ensure safe steel erection. For detailed load calculations, refer to IS 800 and IS 875.

IS 7205: Guidelines for Handling and Storing Materials

1. Secure Loading and Unloading (Clause 5.5)

• Steel elements must be fastened to avoid shifting, sliding, or overturning while in transit.
• Proper sling placement is essential; slings must be appropriate for the steel's weight and type.
• Protect slings from sharp edges using longitudinally cut pipes.
• Use equipment with sufficient capacity and reach.

2. Loading Platforms (Clause 5.24.9)

• Equip platforms with toe-boards and stops for wheelbarrows.
• Ensure materials are loaded securely without overhangs.

3. Handling Small Items (Clause 5.17.2)

• Use bolt baskets or containers with sturdy handles to hold small components like bolts and drift pins to prevent falls.

4. Ramps and Support Structures (Clause 5.2)

• Assess strength and capacity of ramps for vehicles and cranes.
• Ensure supports and bracings are adequate and stable.
• Utilize materials in good condition following safe design guidelines.

Practical Specifications:

flowchart LR
    A[Receiving Steel] --> B[Inspect for Safe Loading]
    B --> C[Secure Steel Placement]
    C --> D[Safe Slinging Practices]
    D --> E[Load on Platforms with Toe-boards]
    E --> F[Use Containers for Small Items]
    F --> G[Unload via Inspected Ramps and Trestles]

Summary: Secure and stable handling with appropriate equipment, sling protection, and structurally sound access minimizes hazards during material handling.

IS 7205: Guidelines for Use and Inspection of Lifting Gear

Key Points:

• Inspection Frequency (Clauses 5.24.6 & 6.1.1):

  • Regular inspections of wire ropes, chains, slings, and lifting tackles are compulsory.
  • Checks should identify wear, corrosion, deformation, or other damage.
  • Equipment showing deterioration must be re-rated with reduced Safe Working Load (SWL) and clearly marked.

• Safe Working Load (Clause 5.25.1):

  • Only use lifting gear that is tested and marked.
  • Never exceed the SWL assigned by the manufacturer or testing authority.

Inspection Checklist Examples:

• Look for broken wires in ropes.
• Inspect chains for elongation and cracks.
• Examine slings for cuts or deformation.
• Verify certification and markings.

Indicative SWL Reduction for Wire Ropes:

Inspection Workflow

flowchart TD
    A[Begin Use of Lifting Gear] --> B[Inspection by Responsible Person]
    B --> C{Is Condition Acceptable?}
    C -- Yes --> D[Use Within SWL]
    C -- No --> E[Mark Reduced SWL or Discard]
    E --> F[Retest or Replace]
    D --> G[Safe Lifting]

Note: Frequent inspection and adherence to SWL are vital for safe operations under IS 7205.

Essential Bracing and Guying Practices under IS 7205

1. General Procedures (Clause 6.0):

• Guy the first roof truss on both sides before removing hoisting ropes.
• After erecting subsequent trusses and purlins, fit protective guides and wind bracing to withstand sudden gusts.
• Maintain bracing and guying until the structure is fully completed.
• Guy trusses immediately after erection to avoid instability.
• Do not overload temporary structures storing materials.

2. Guying Materials (Clause 5.23.2):

• Use wire ropes conforming to IS: 2266-1970 or manila ropes per IS: 1084-1969.

3. Temporary Bracing (Clause 6.1.3):

• Provide temporary braces to resist stresses from erection equipment and applied loads.

4. Anchor Verification (Clause 5.4):

• Check that anchors are properly positioned and concrete weights prevent uplift and sliding.

Typical Guy Rope Tension Calculation:

[ T = \frac{W \times H}{L \times \cos \theta} ]

Where:

• (T) = tension in guy rope
• (W) = lateral wind or applied force
• (H) = height of attachment
• (L) = guy rope length
• (\theta) = angle between rope and horizontal

Guy Rope Characteristics Table (IS Standards):

flowchart LR
    A[Begin Erection] --> B[Guy First Truss Both Sides]
    B --> C[Hoist Subsequent Trusses]
    C --> D[Install Protective Guides]
    D --> E[Fit Wind Bracing]
    E --> F[Continue Erection and Guying]

IS 7205: Fire Prevention and Safety During Steel Erection

Clause 5.20 Highlights:

• Establish a fire protection plan before commencing flame cutting, burning, heating, forging, riveting, or similar tasks.
• Prohibit workers from throwing hot materials such as rivets or cigarettes.
• Assign a trained fire watch to monitor for sparks or flames during hot operations.
• Keep suitable fire extinguishers (e.g., CO2, foam) readily accessible.
• Clear flammable materials from at least a 10-meter radius around hot work.
• Ensure adequate ventilation to prevent accumulation of flammable gases.

Fire Safety Checklist:

Additional Notes:

• Implement hot work permit systems to control fire safety.
• Apply fireproofing to steel elements if required by design codes.

flowchart TD
    A[Initiate Hot Work] --> B{Is Fire Protection Plan in Place?}
    B -- Yes --> C[Assign Fire Watch]
    B -- No --> D[Halt Work]
    C --> E[Remove Flammable Materials]
    E --> F[Position Fire Extinguishers]
    F --> G[Conduct Hot Work Safely]
    G --> H[Monitor Post-Work for 30 Minutes]
    H --> I[Complete]

Summary: IS 7205 stresses strict fire safety procedures, effective training, and vigilant fire watch during hot operations to prevent fires on steel erection sites.

Welding and Gas Cutting Safety as per IS 7205

• Training: Welders and gas cutters must be trained in accordance with IS: 818-1961 for safe welding practices.

• Safety Procedures: Follow guidelines from IS: 3016-1965 to prevent accidents during welding and cutting.

• Protective Gear:

  • Use gloves, safety boots, aprons, and hand shields as mandated by IS: 1179-1967.
  • Hand shield filter glasses should comply with IS: 5983-1971 and suit the user’s eye sensitivity.

Safety Requirements Summary:

Additional Recommendations:

• Inspect equipment before use.
• Ensure proper ventilation to avoid toxic fumes.
• Store gas cylinders upright and secure them properly.

flowchart LR
    A[Training as per IS:818-1961] --> B[PPE Use per IS:1179-1967]
    B --> C[Follow Precautions per IS:3016-1965]
    C --> D[Use Filter Glass as per IS:5983-1971]
    D --> E[Ensure Safe Operations]

This structured approach significantly reduces risks during welding and cutting activities.

IS 7205: Training and Competency Requirements for Steel Erection Personnel

1. Training for Supervisors (Clause 3.1):

• Supervisors must be trained to enforce safety measures and recognize safe and unsafe work practices.
• New workers should undergo an induction covering general safety rules and demonstrations of safe methods.
• Monitor new workers continuously to ensure compliance.

2. Training for Operators and Slingers (Clauses 5.24.1 & 5.24.2):

• Crane and lifting equipment operators must receive training on safe operation.
• Slinging personnel should be trained in proper slinging techniques.
• Follow safety codes such as the Indian Standard Code of Practice for Safe Use of Cranes.
• Employ a strict hand signaling system with only one designated signaler and no verbal commands.

3. Legal Compliance (Clause 4.1):

• Adhere to all applicable statutory safety regulations alongside IS 7205.

Training Summary Table:

flowchart TD
    A[Induction for New Workers] --> B[Safe Method Demonstration]
    B --> C[Performance Monitoring]
    D[Supervisor Training] --> E[Safety Enforcement]
    F[Operators and Slingers Training] --> G[Safe Operation]
    G --> H[Use Hand Signals]
    H --> I[Single Signal Person]

References:

• IS 7205 Clauses 3.1, 4.1, 5.24.1, 5.24.2
• Indian Standard Code of Practice for Safe Use of Cranes (in preparation)

IS 7205: Emergency Response for Steel Erection Sites

While specific formulas or tables for emergency procedures are not provided, key points include:

• Risk Awareness: All personnel must be informed about fire hazards.
• Emergency Contacts: Staff should know the nearest fire station's contact information.
• Preparedness: Establish clear procedures to quickly alert emergency services.

Recommended Best Practices:

Emergency Response Flow:

flowchart TD
    A[Detect Emergency] --> B[Notify Supervisor]
    B --> C[Call Fire Brigade]
    C --> D[Evacuate Site]
    D --> E[Use Fire Extinguishers if Possible]
    E --> F[Await Emergency Services]

Summary: IS 7205 stresses emergency awareness and rapid communication but relies on general safety practices for detailed emergency handling.

IS 7205: Inspection and Maintenance Guidelines

• Clause 5.24.6:

  • Conduct scheduled inspections of wire ropes, chains, slings, and lifting tackles.
  • Mark old or deteriorated tackles with reduced Safe Working Load (SWL).

• Clause 5.24.7:

  • Maintain trucks, jacks, lifts, and cranes in good working order through regular servicing.

• Clause 6.1.1:

  • The responsible person must inspect lifting gear before use to verify fitness and capacity.

Typical Inspection Checklist:

Formula for Reduced Capacity:

[ \text{Reduced SWL} = \text{Original SWL} \times (1 - \text{Percentage of deterioration}) ]

flowchart TD
    A[Begin Inspection] --> B{Equipment Type}
    B -->|Wire Rope| C[Check for Broken Strands & Corrosion]
    B -->|Chain| D[Check for Elongation & Cracks]
    B -->|Sling| E[Check for Cuts & Abrasions]
    B -->|Crane/Jack| F[Check Mechanical Components]
    C --> G{Defective?}
    D --> G
    E --> G
    F --> G
    G -- Yes --> H[Mark Reduced SWL or Replace]
    G -- No --> I[Declare Fit for Service]
    H --> J[Record and Report]
    I --> J

IS 7205: Appendices and Reference Materials

• Emergency Jointing (Clause 6.1.5.3): In urgent cases such as impending floods before riveting completion, secure joints by:

  • Filling 40% of rivet holes with cylindrical drifts
  • Filling an equal number with fully tightened service bolts

• Related Standards:

  • Indian Railway Standard for bridge girder erection and riveting (Serial No. B2-63)
  • Safety procedures for steel structural erection

• Contact Information:

  • BIS Headquarters: Manak Bhavan, New Delhi
  • Regional offices in Delhi, Kolkata, Chennai, Mumbai, Bangalore, etc.
  • BIS website: bis.org

Emergency Jointing Quick Reference Table:

For detailed erection or lifting appliance tables and formulas, consult Clause 5.24 of IS 7205 and Indian Railway Standard B2-63.

flowchart TD
    A[Emergency Situation] --> B[Fill 40% Rivet Holes with Drifts]
    B --> C[Fill Equal Holes with Service Bolts]
    C --> D[Tighten Bolts Fully]
    D --> E[Provide Temporary Secure Joint Until Riveting Completes]

This protocol ensures structural safety under critical conditions prior to permanent riveting.