Mining Safety Essentials.pdf

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MINING SAFETY ESSENTIALS | 00

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MINING SAFETY ESSENTIALS | 0302 | LEIGHTON CONTRACTORS

CONTENTSintroduction 04

Safety and Health at Leighton Contractors 04The Mining Safety Essentials 04The Essential Behaviours 04The Mining Safety Essentials at work 04

Mining Safety eSSentialS 06

1. Confined spaces 062. Cranes and lifting operations 083. Electrical safety 104. Explosives and blasting 12 5. Ground control 146. Mine traffic and roadways 167. Mining operations 188. Mobile assets 209. Plant safeguarding and isolation of energy 2210. Tyres 2411. Working at heights 26

DEvELOp AND IMpLEMENT WORkING AbOvE THE LINE CONTROLS.

IMpLEMENT THE REquIREMENTS OF THE MINING SAFETY ESSENTIALS.

IN ExCEpTIONAL CIRCuMSTANCES, WHERE COMpLIANCE TO A MINING SAFETY ESSENTIAL REquIREMENT IS NOT pOSSIbLE, A WRITTEN ESSENTIAL ExCEpTION IS REquIRED FROM THE GENERAL MANAGER WHO HAS LINE ACCOuNTAbILITY FOR THE pROjECT.

Safety and health at leighton contractorS

Thinking and working safely is part of our culture. Our first and most important value is safety and health above all else, and through its guiding behaviours, we make it clear to our leaders and team members that:

� we look after our workmates as if they are family

� we take action when we see a safety risk.

The goal of our framework is Zero Harm—and our focus is on eliminating the potential for fatalities and permanent disabilities, while systematically reducing all other injuries.

the Mining Safety eSSentialS

Leighton Contractors’ Mining Safety Essentials are the minimum, non-negotiable requirements on how we manage critical risk in our business. They are the areas we have identified from our 30 years’ experience in contract mining that give rise to severe consequences if they are not clearly understood and applied.

They reinforce our systems and processes—they do not replace them. Nothing replaces the need for everyone to proactively manage risk every day, in every task they undertake.

It’s about realising a step change in our safety performance.

the eSSential BehaviourS

Every Mining Safety Essential has defined behavioural expectations for those directly involved in doing the work (Working Behaviours), and those who plan, coordinate, schedule or manage the critical risk activity.

You must be familiar with and adhere to the behaviours relevant to your role at all times.

For more information, please refer to your Essential Behaviours pocket guide, as well as consult regularly with your supervisor and SHE representatives.

the Mining Safety eSSentialS at work

FRONTLINE LEADERSHIp

It is important to remember that we all need to show commitment and leadership when it comes to safety, and that we will all need to be the ambassadors and champions of the Mining Safety Essentials if we are to succeed.

In addition, critical risk activities require a higher level of supervision, and frontline leaders overseeing critical risk activities must ensure that, prior to any work commencing, their people and teams:

� have been consulted � have been provided with an

opportunity to comment on the proposed system of work

� have received the work instructions and understand them

� are trained and authorised to undertake the work

� fully understand the risks and controls.

ACCOuNTAbILITY AND COMpLIANCE

The Mining Safety Essentials requirements are non-negotiable, and all Leighton Contractors’ employees and subcontractors need to adhere to them at all times.

You are encouraged to discuss any issues of concern with your supervisor, and also bring forward your innovations and ideas, so that we can continuously improve.

You also have an obligation to report any breaches to your supervisor.

It is expected that while carrying out critical risk activities, you will comply with the Mining Safety Essentials and the relevant external and internal obligations, including Statutory Acts and Regulations, Australian Standards, Codes and Practices, our company business standards, and client requirements.

Where the expectations prescribed in these documents are exceeded by the Mining Safety Essentials, the Mining Safety Essentials requirements will take precedence.

Within the Mining Division, processes exist to assist with the implementation of the Mining Safety Essentials and the effective management of critical risk.

These processes need to be complied with. They include, but are not limited to, the:

� exceptions process � permit to work process � change management processes

(e.g. modify fixed or mobile plant processes).

IDENTIFICATION OF HAzARDS AND ASSESSMENT OF RISk

As defined in the Mining Safety Essentials, activities containing a critical risk will:

� be supported by a risk assessment conducted by competent person(s)

� be captured in Active Risk Manager (ARM) with a nominated Risk Owner

� have a work instruction that describes the controls identified by the risk assessment to manage the critical risk(s)

� have a monitoring and review schedule.

Prior to commencing any critical risk activity you must complete a risk assessment.

INNOvATION: uSING ENGINEERING TO HELp ELIMINATE RISk

Where Leighton Contractors is responsible or has the capacity to influence, all opportunities to design out critical risks should be fully explored.

This includes, but is not limited to:

� designing out the need to access/work at heights, or in confined spaces

� designing adequate walkways and work platforms

� ensuring that lockable isolation mechanisms and fail safe systems installed on plant and electrical installations are fitted

� programming project schedules, sequencing and techniques to utilise in-situ permanent facilities, rather than relying on temporary measures (e.g. temporary access scaffolds)

� managing vehicle interactions, as part of intersection and pit design.

TRAINING AND AuTHORISATION

Competencies required for persons involved in a critical risk activity must be documented. These include national competency units.

All persons undertaking critical risk activities, as defined in the Mining Safety Essentials, are required to undergo a verification process to confirm they have the required competencies to work safely before being authorised.

Authorisation is required from the project manager, project manager’s delegate, or a person detailed in the Safety and Health Management System.

Training that is outsourced should only be conducted by approved third party providers.

ExCEpTIONS (WITH ExECuTIvE AppROvAL ONLY)

In exceptional circumstances, where compliance to a Mining Safety Essential requirement is not possible, a written Essential Exception is required from the general manager who has line accountability for the project.

TECHNICAL SuppORT

If you require additional technical support, please contact the SHE advisors at your project, or email one of the nominated technical support contacts listed on Our Way.

Note: The term ‘process’ is used throughout this document in reference to any formal process or procedure that exists within Leighton Contractors, or its project management system, including (but not limited to) Our Way processes, standard operating procedures (SOPs), or Work Instructions and other procedures.

HIERARCHY OF CONTROL

When assessing the risks to determine controls, your first consideration should always be to eliminate the risks whenever possible.

IF THIS IS NOT pOSSIbLE:

IF THIS IS NOT pOSSIbLE:

IF THIS IS NOT pOSSIbLE: (AND AS A MINIMuM)


INTRODuCTIONIN

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context and application

This Mining Safety Essential applies to all Mining Division projects, activities, subcontractors and visitors.

It describes minimum requirements and Above the Line principles associated with entering or working in confined spaces to prevent:

� unsafe atmospheres or engulfment � increased risk of explosion � exacerbation of other risks due to

access/area restrictions.

MiniMuM requireMentS

Note: Where the minimum requirements cannot be implemented, an Essential Exception Form shall be signed and approved by the general manager.

1.1 A confined space process shall be developed, based on a risk assessment that includes:

� survey to identify confined spaces � confined space register � confined space permits � roles and responsibilities � response plan testing.

1.2 A site survey shall be undertaken by an authorised person to identify all confined spaces (e.g. fixed and mobile plant and equipment, work areas and infrastructure).

1.3 A confined space register shall be developed and reviewed at least annually or when modifications or new plant and equipment are introduced. The register shall include:

� photos of identified confined spaces � known hazards � rescue plans.

1.4 Confined spaces identified in the register shall have visible confined space entry signs with a unique identifier at or near the entrance.

1.5 The rescue plan shall be developed for identified confined spaces and include:

� methods of communication between the worker, stand-by person and external support

� special equipment � entry and exit strategies � response times.

1.6 All personnel who conduct confined space activities shall be competent and authorised.

1.7 A permit shall be completed for all confined space activities and the permit issuer shall be authorised by the project manager. The permit shall consider:

� risk management plan � ventilation plan � rescue plan � ongoing atmospheric testing � entry/exit log.

1.8 A stand-by person shall be dedicated to a confined space activity and shall not:

� leave the confined space area unattended

� enter the confined space at any time.

1.9 Atmospheric testing equipment shall be used, tested and calibrated in accordance with the manufacturer’s requirements.

aBove the line principleS

Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with entering or working in confined spaces are:

Eliminate Get rid of

Redesign confined space so that it would no longer be defined as one

Modify related work activities to eliminate the need to enter the space

Use cameras for inspections

Use high pressure or high volume hoses for cleaning

Scrape surfaces rather than using solvents

Use intrinsically safe equipment in potentially flammable atmospheres

Locked isolation points

Physical barriers at entry points

Purge the atmosphere of the confined space prior to entry

Continuous ventilation of confined space during entry and working

Confined space procedure

Site survey

Confined space register

Rescue plan and stand-by person

Confined space permit

Atmospheric testing

Trained and authorised personnel

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Engineering Engineered controls

Administrative controls

Instructions and signs

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CONFINED SpACE:

Is defined by Australian Standard 2865:2009 as an enclosed or partially enclosed space that is not intended or designed primarily for human occupancy, and within which there is a risk of one or more of the following:

� an oxygen concentration outside the safe oxygen range

� a concentration of airborne contaminant that may cause impairment, loss of consciousness or asphyxiation

� a concentration of flammable airborne contaminant that may cause injury from fire or explosion

� engulfment in a stored free-flowing solid or a rising level of liquid that may cause suffocation or drowning.

STAND-bY pERSON:

A person who:

� holds relevant and current competencies

� is assigned to and remains on the outside of and in close proximity to the confined space

� is capable of being in continuous communication with and, if practicable, able to observe persons inside the confined space

� is capable of operating monitoring equipment used to ensure safety during entry to and work in the confined space

� is capable of initiating emergency processes (including rescue processes) if necessary.

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1. CONFINED SpACES



It describes minimum requirements and Above the Line principles to ensure all lifting operations are conducted safely and to prevent:

� personnel being struck by a crane or load

� cranes over-turning or collapsing � cranes or loads contacting

other structures � uncontrolled fall of a load.



2.1 There shall be a process for all lifting operations on site to ensure lifting operations are conducted safely.

2.2 A pre-lift assessment shall be conducted by a competent person for all lifting operations to assess lift risks, determine controls and plan the lift.

2.3 Cranes shall not lift above 85 per cent of the rated capacity of the crane at any time or radius.

Note: This requirement does not apply to overhead travelling cranes, portal cranes or tower cranes.

2.4 High Risk Lifts shall have a Lift Plan and a risk assessment that is approved by a person authorised by the project manager.

2.5 For High Risk Lifts, the accuracy of load indicators shall be verified prior to commencing the lift activity or when the crane configuration is modified.

Note: Verification shall be undertaken by performing a test lift with a suitable known weight, or by using a verification process endorsed by the crane manufacturer.

2.6 Crane operators, dogmen and riggers shall hold the relevant licence and be authorised.

2.7 For pick and carry activities, the operator shall assess the entire route to ensure the crane remains within its capacity at all times. 2.8 Loads shall be adequately secured to prevent personal damage or loss of load.

2.9 Loads shall not be suspended or lifted over personnel unless they are in a protected area or where controls are established to prevent personnel being struck.

2.10 Cranes shall be fitted with a physical locking system that disables and isolates its free-fall capability.

2.11 Cranes shall only travel, set up and perform lifts on ground where the ground conditions are adequate to support the crane. Where the crane operator determines the ground may be unsuitable a formal assessment of the ground bearing capacity shall be made.

2.12 Outriggers shall be packed and supported as per the manufacturer’s and/or engineer’s recommendations.

2.13 Physical barriers shall be used to protect outriggers if a risk of vehicle or plant striking the crane cannot be adequately controlled.

2.14 Slings, chains, spreader bars and other lifting gear shall only be used if they:

� comply with applicable Australian Standards

� have clearly marked the rated capacity that is suitable for use on the specific crane

� have been inspected and for non-consumable items, tagged and certified for use by a competent person.

2.15 Personnel shall not attach a load to lifting equipment unless authorised.

2.16 Vehicle loading cranes shall have engineering controls to protect the operator from crush injury during lifting operations.

2.17 Earth moving equipment and other ancillary plant shall not be used as lifting equipment unless they:

� are marked with a Safe Working Load (SWL) and/or Working Load Limit (WLL) on the lifting attachment/point

� have a load chart displayed in the cabin

� are fitted with load lock valves.

2. CRANES AND LIFTING OpERATIONS


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with cranes and lifting operations are:

pRE-LIFT ASSESSMENT:

Identification and assessment of potential hazards/risks associated with a lifting operation or sequence of lifts.

RATED CApACITY:

Based on the Australian Standard compliant load chart, and where a crane is de-rated (i.e. multi-crane lifts, crane articulation), the 85 per cent SWL applies to the re-rated capacity.

HIGH RISk LIFTS:

� any lift where a mobile crane would be operating at >75 per cent of its safe working load; or

� any lift where a tower crane would be operating at >85 per cent of its safe working load; or

� multiple crane lifting; or � suspending personnel in a man

cage/box; or � where defined as a High Risk Lift

by the project.

pROTECTED AREA:

An area where there are physical controls in place to prevent persons being struck/crushed by a falling load.

LICENCE:

A permit issued from an official external authority that is current and carried on the person at all times.


Plan work to reduce the number of lifts

Use of technology to remove operator from lifting zone

Use of specialised jacking equipment

Physical barriers preventing access to operating cranes and lifting zones

Overhead protective structures

Crane isolator and free fall lockouts

Certified lifting lugs and equipment

Engineered crane operation pads

Lifting procedure

Pre-lift assessment

Approved Lift Plan

Ground condition assessment

Safe working load signs

Inspections


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It describes minimum requirements and Above the Line principles to prevent:

� personnel contacting concealed electrical services

� contact with live electrical equipment or exposed electrical conductors

� arcing or explosions from faulty or poorly maintained equipment

� contact with overhead electrical cables.

This Mining Safety Essential does not apply to extra low voltage work.



3.1 Electrical work shall only be conducted by appropriately licensed and authorised electricians, who also hold a current certificate in:

� low voltage rescue � senior first aid.

3.2 With the exception of fault finding and performance testing, live work on electrical equipment shall not be carried out.

3.3 Fault finding or performance testing on electrical equipment shall not be carried out in an energised state unless all reasonable alternative means of carrying out the work have been exhausted.

3.4 Before fault finding or performance testing on electrical equipment can be undertaken in an energised state, a process for the specific task shall be developed, based on a risk assessment that includes:

� identification of suitable tools, testing equipment and personal protective equipment

� presence of an observer trained in CPR and the rescue plan

� insulation of energised conductors where necessary to prevent inadvertent contact or flashovers

� use of physical barriers to isolate the area to prevent unauthorised personnel from entering

� use of tags indicating live testing is in progress.

For the purpose of this requirement, a test to re-energise (test for dead) to confirm that equipment is de-energised or isolated is not considered live work.

3.5 Electrical equipment and earthing systems shall be inspected and maintained in accordance with relevant Australian Standards and original equipment manufacturer requirements.

3.6 Earth leakage protection shall be installed on all circuits where there is a potential to contact live conductors.

3.7 Electrostatic earthing shall be provided for all situations or structures where static discharge presents a hazard.

3.8 All electrical supply shall be provided with a means of positive isolation and be clearly labelled.

3.9 Enclosures with exposed conductive parts shall only be accessible with the use of a key or tool.

3.10 A test to re-energise (test for dead) shall be conducted to confirm the equipment is isolated.

3.11 A permit to work is required for carrying out:

� high voltage activities � work within the vicinity of overhead

power lines and concealed power cables.

3.12 A prescribed sequential switching of high voltage equipment shall be controlled through a switching program.

3.13 A survey of all overhead power lines shall be conducted and recorded in a register.

3.14 Where overhead power lines cross surface roads, they should be relocated, buried or elevated to a safe height. Where this is not practical, clearance heights shall be recorded in the site register, pre-warning clearance indicators shall be fitted and regular surveys conducted to monitor clearance heights.

3.15 Warning signs and where applicable pre-warning clearance indicators shall be installed at locations where there is potential to contact overhead power lines and concealed power cables.

3.16 Electrical equipment and electrical testing equipment shall be inspected and recorded in a register.

3.17 Electrical equipment that can be plugged into a power outlet shall be tested and tagged.

3.18 Electrical cables used as trailing/ reeling cables on mobile equipment or any other equipment where the supply cable may be exposed to the risk of damage due to tension must be fitted with Earth continuity protection.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with working safely with electricity (including electrical equipment) are:

ExTRA LOW vOLTAGE:

Voltage less than 50V AC or 120V DC, unless otherwise prescribed in the relevant legislation.

LOW vOLTAGE:

Voltage of at least 50V AC or 120V DC, but not more than 1000V AC or 1500V DC, unless otherwise prescribed in the relevant legislation.

HIGH vOLTAGE:

Voltage greater than 1000V AC or 1500V DC, unless otherwise prescribed in the relevant legislation.

LICENCE:


LIvE WORk:

Work on electrical equipment that is energised at normal operating potential.

pOSITIvE ISOLATION:

A method of isolation where there is zero potential of energy at the workplace and:

� all dangerous energy has been identified

� all dangerous energy is isolated at the source

� residual energy has been eliminated or controls are in place to prevent uncontrolled energy release.

SAFE HEIGHT:

A ground clearance that would permit vehicles on site or using the roadway to travel under the overhead conductor without encroaching within the relevant exclusion zones (subject to conductor voltage, environmental conditions and equipment).

REELING CAbLE:

A cable specifically designed to be frequently reeled on and off a cable drum or reeler on mobile apparatus.

TRAILING CAbLE:

A cable specifically designed to be moved in conjunction with mobile apparatus.


Relocate overhead high voltage electrical cables underground

Redesign low voltage control systems to extra low voltage systems

Fence or secure high voltage installations and sub-stations

Lockable isolation points on electrical equipment

Surge arrestors

Earth leakage protection

Earthing equipment

Installation of shrouds on exposed electrical components

Testing and tagging of portable electrical equipment

Test to re-energise (test for dead)

Isolation procedure

Permit to work—high voltage and for work near overhead power lines

Warning signs and indicators for overhead power lines

Sequential switching of high voltage equipment


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3. ELECTRICAL SAFETY




� unauthorised access by personnel into security sensitive ammonium nitrate (SSAN) storage, loading and blasting areas

� unplanned initiation or misfires of explosives

� damage caused by flying debris.



4.1 There shall be a management plan for explosives based on a risk assessment that addresses the:

� transport of explosives � use of explosives � security of explosives.

4.2 Explosives areas shall be demarcated and access restricted to authorised personnel.

4.3 Each site shall prescribe minimum distances for the placement of fencing, bunding and signage around blast holes to restrict plant and prevent unauthorised access.

4.4 Minimum blast exclusion zones (including operational information such as firing times and locations) shall be defined and communicated to all personnel on site, and there shall be a verification process to ensure exclusion zones are clear prior to firing.

4.5 Personnel transporting, storing and using explosives and SSAN shall be licensed and authorised.

4.6 The drill and blast planning process shall include approved:

� drill plans � blast designs � development breakthrough plans for

underground operations.

4.7 The blasting process shall include:

� establishment of exclusion zones � blast guard plan � communication of firing times and

locations � requirement to verify that exclusion

zones are clear of personnel � firing line hook up.

4.8 For blasting activities undertaken on surface operations, there shall be a lightning detection device and associated process.

4.9 Barricading and signage shall be erected to prevent access to underground break through areas, including production, raise bore, diamond and development drill holes.

4.10 There shall be a process to manage misfires that includes:

� barricading and signage in place � communication to all affected

personnel � rectification by a competent and

authorised person � documenting misfires in a misfire

record.

4.11 There shall be a decontamination process for equipment used for the transport, storage and use of explosives prior to any hot work being conducted.

4.12 There shall be a specific process for inspecting and maintaining all equipment used with explosives.

4.13 Vehicles carrying explosives shall only park in designated areas. Designated areas shall not include:

� administration areas � maintenance workshops � accommodation areas.

4.14 There shall be a process for re-entry into underground work areas after blasting that includes:

� atmospheric testing for harmful gases � respirable dust is cleared � ventilation integrity � ground conditions are stable � inspection for misfires.

4.15 There shall be a process for the management of fumes for surface operations that includes:

� selection of product � blast design � loading techniques � fume plume exclusion zones.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with explosives and blasting activities are:

ExCLuSION zONE:

A zone to protect personnel and plant from entering the blasting area.

LICENCE:


bLAST GuARD:

Authorised and competent person located at the appropriate position to prevent entry to the blast exclusion zone.

ExpLOSIvES AREA:

An area where explosives are located.

HOT WORk:

� grinding � welding � thermal or oxygen cutting or heating � other related heat-producing or spark-

producing operations.


Non explosive mining techniques

Use of alternative blast products

Secured explosive storage areas

Segregated park up areas for vehicles carrying explosives

Physical barriers for drill patterns and loading areas

Blast guards to prevent access to blast areas

Barricading of misfires

Explosives handling and loading equipment

Lightning arrestors and detection devices

Remote detonation

Explosives management plan and related procedures

Drill and blast design

Inspection and maintenance of equipment used with explosives

Hot work permit for maintaining explosive vehicles and equipment


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4. ExpLOSIvES AND bLASTING



It describes minimum requirements and Above the Line principles for underground and surface operations to prevent:

� wall failures, slumping and rock falls � engulfment of personnel or plant � personnel falling into voids or old

workings � rock bursts � failure of ground support � personnel being struck by

falling material.



5.1 A geotechnical engineer shall establish the geotechnical parameters for the mine design.

5.2 There shall be a management plan for ground control based on a risk assessment that addresses:

� geotechnical designs and factors � ground control methods and support

standards � the interaction of surface and

underground activities � old workings � seismic activity � environmental factors � operational parameters � the monitoring and analysis of

ground condition data and excavation stability.

5.3 The ground control management plan shall be:

� developed in conjunction with geotechnical personnel

� authorised by appointed persons � reviewed by third party geotechnical

personnel annually � reviewed by geotechnical personnel

after a significant ground failure � aligned with the mine design and

mining activities � readily available and communicated

to all personnel.

5.4 There shall be a process to ensure personnel are not exposed to unsupported ground or where there is potential to be affected by fall of ground.

5.5 Personnel installing ground support shall understand ground control methods and/or support standards.

5.6 There shall be a process to prevent personnel from entering exclusion zones at the toe of high walls and dumps and open faces of excavations.

5.7 Designated personnel shall be trained to visually inspect the ground conditions of their work area.

5.8 There shall be a process to manage loose rock that has the potential to cause harm.

5.9 There shall be a preventative maintenance and calibration process to ensure all ground control equipment is calibrated, maintained and in a serviceable condition.

5.10 Changes to mine design or operational practices shall follow the change management process which includes:

� authorisation by competent personnel � updating of site plans � communicating to affected personnel.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with underground and surface ground control are:

AppOINTED pERSON:

As determined by the project manager.


Use of remote technology for operational tasks

Use of alternative/improved standard of ground control

Ramps or roads not located adjacent to high walls

Physical barriers to prevent entry to high risk areas

Physical barriers to prevent materials from entering work areas

Slope (angles) of walls

Height and width of dumps and benches

Remote monitoring of wall movements

Falling object protective structures (FOPS) for mobile equipment

Mine design

Ground control management plan

Monitoring and inspection of ground control


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5. GROuND CONTROL



It describes minimum requirements and Above the Line principles that promote the safe operation of vehicles on site, and to ensure that mine roadways are designed and maintained to prevent:

� collisions between mobile equipment and/or light vehicles travelling on mine roadways

� loss of control of vehicles � vehicles travelling over unprotected

edges � vehicles striking overhead hazards/

structures � personnel being struck by vehicles.

Note: Requirements for the management of specific risks associated with mobile equipment in active mine areas are addressed in Mining Safety Essential 7. Mining operations.



6.1 There shall be a management plan for traffic and mine roads based on a risk assessment that addresses:

� road design and construction � traffic rules � maintenance and watering of roads � traffic control plans.

6.2 The road design and construction process shall provide for:

� separation of light vehicles and heavy mobile equipment, where practicable

� the use of bunds, adequate shoulder gradients or other controls to prevent a vehicle accidently leaving the road

� maximisation of intersection sight distances

� stop signs or signals used for managing right of way at intersections

� intersections designed to terminate at 90° (± 5°)

� establishing minimum road widths, and when this is unable to be achieved, speed restrictions and/or other controls shall be used to manage right of way

� ensuring established maximum road gradients are not being exceeded

� ensuring superelevation is appropriate for speed and radius of corners.

6.3 A permit system shall restrict and control light vehicle access to work areas.

6.4 Within active mining areas on surface mines, light vehicles shall only park in designated, bunded locations.

6.5 Vehicles shall be parked in a fundamentally stable manner.

6.6 Haul trucks shall not reverse without the use of a spotter, except when receiving and discharging loads or in other prescribed reversing areas.

6.7 An overtaking process shall be established that includes the requirement for positive two-way communication and locations where overtaking shall not occur.

6.8 Controls shall be established to prevent uncontrolled movement of broken down vehicles.

6.9 A risk assessment shall be conducted prior to recovering and towing heavy mobile equipment.

6.10 Warning signs and where applicable pre-warning clearance indicators shall be installed at locations where overhead structures cross surface roads.

6.11 Vehicle height stickers shall be affixed inside the cabins of mobile equipment.

6.12 Road maintenance activities shall not be undertaken without controls in place to protect the road maintainers and other road users.

6.13 Only water trucks incorporating a regulated (smart) watering system approved by the Plant Department shall be used to regulate the application of water on haul truck roadways.

6.14 A risk assessment shall be conducted to establish Traffic Control Plan layouts for identified high traffic volume/high hazard areas. These areas may include (but are not limited to):

� run of mine � heavy mobile equipment go-lines � service and refuelling areas � workshops � infrastructure areas � complex intersections � intersections with public roads.

The risk assessment shall include the interaction of mobile equipment, light vehicles and pedestrians, while giving priority to their physical separation (i.e. solid barriers, bunding or exclusion zones).

6.15 Traffic management and/or road design changes shall be communicated to all affected personnel.

6.16 Road inspections shall be undertaken on a regular basis to confirm that road design and construction criteria are maintained.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with mine traffic and roadways are:

FuNDAMENTALLY STAbLE:

A light vehicle is fundamentally stable when it can be left unattended without the possibility of it moving under the influence of gravity. In addition the vehicle engine must be turned off, the transmission must be engaged in park or first gear and the park brake applied.

Mobile equipment is fundamentally stable when it can be left unattended without the possibility of it moving under the influence of gravity by applying the park brake, placing the transmission in park (if applicable) and one or more of the following controls:

� wheels in a V drain or over a hump � Ground engaging tools (GETs) lowered � wheels turned in against a suitable bund

� wheels suitably chocked (except for on grade situations)

� for rubber tyred mobile equipment on grade, a suitable bund established downgrade of and against the wheels.

For underground operations mobile equipment must be angled toward the tunnel walls.

For maintenance activities that require the vehicle engine to be running, potential movement must be controlled in accordance with the Live Testing process.

pRESCRIbED REvERSING AREAS:

Reversing areas as identified in site processes (e.g. heavy mobile equipment go-lines or workshops).

ACTIvE MINING AREAS:

The area of influence for heavy mobile equipment (self propelled, off highway mining and earthmoving equipment) actively performing mining work, including:

� excavation areas � dumping areas � production dozing areas � scraper circuits � other mining areas nominated by

the project manager.


Road and intersection design

Segregation of light vehicles from active operating areas

Designated walkways

Bunds and physical barriers

Regulated spray bars on water trucks

Traffic and road management plan

Road design and construction procedure

Traffic control plans

Overtaking procedure

Warning signs and clearance indicators

Vehicle height stickers

Road inspection and maintenance program

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6. MINE TRAFFIC AND ROADWAYS

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It describes minimum requirements and Above the Line principles for underground and surface operations to prevent:

� collisions between plant and/or light vehicles, and/or pedestrians in active mining areas

� engulfment of personnel or plant � plant falling into voids, over pit walls

or dumps � failure of dumps � personnel, plant or light vehicles

being struck by falling material.


7.1 There shall be a process for performing excavator operations that includes:

� the bucket being stationary and either engaged or grounded while ancillary plant is within an excavator’s swing radius

� positive communication being utilised for ancillary plant working in an excavator’s swing radius

� an excavator not slewing its bucket over the cabin of other equipment.

7.2 There shall be a process for performing front end loader operations that includes:

� excavation faces being no higher than the maximum bucket reach of the front end loader

� a front end loader not passing its bucket over the cabin of other equipment

� when reclaiming from the base of an excavation face, dump or stockpile, physically restricting access of rubber tyred plant and vehicles to the area above.

7.3 There shall be a process for performing truck dumping operations that includes:

� prohibiting the practice of jump dumping

� on approach, truck operators observing dumps for signs of cracking, slumping and inappropriate bundwall heights. If observed, loads shall be dumped short and the supervisor notified

� truck operators reversing square to the bundwall and not using the bundwall as a brake

� dump dozer operators constructing and maintaining bundwalls on tip-heads with sufficient integrity and to the required height dimensions (minimum half wheel height of the largest truck using the dump)

� physically restricting access below dumping operations

� conducting a JSEA that considers geotechnical risks and involves appropriately authorised personnel prior to:

- dumping into a body of water - dumping over or near pit wall

crests (note: a pit wall must not be ‘directly’ dumped over, material must always be dumped short and pushed over a pit wall).

7.4 There shall be a process to prohibit trucks being driven down a ramp when overloaded.

7.5 There shall be a process for performing stockpile operations that prohibits equipment from operating over a valve draw cone.

7.6 Dumping hoppers must have an adequate physical barrier (e.g. stop block) designed to prevent equipment contacting or entering the hopper when discharging loads.

7.7 Processes must be established that consider the following general requirements:

� rubber tyred dozers must not be used to ‘directly’ push over pit walls

� appropriate bundwalls or physical restrictions must be established along exposed or open excavation edges where drills, rubber tired plant and vehicles can access these areas

� when pedestrians and light vehicles enter active mining areas, giving consideration to positive communication requirements and the ceasing of mining activities while they remain in the area

� operators must remain in the cabin of trucks during the physical process of loading

� access to areas below any bench edge or wall must be physically restricted where operations above may result in material falling over that bench edge or wall.

7.8 There shall be a process for performing underground operations that includes:

� installation of fire suppression systems on all plant and equipment with an engine output >125kW

� storage and/or disposal of flammable materials

� provision of a healthy breathable atmosphere

� adequate water inrush flood mitigation design considerations for working entrances

� identification of natural or manmade voids that may contain noxious atmospheres or water

� treating tailings materials used for backfill to prevent liquefaction and have engineered designed bulkheads for containment

� barricading areas that could be exposed to unplanned drilling breakthrough

� physically restricting access to exposed edges, shafts and holes

� access to areas below any shaft or hole must be physically restricted where operations above may result in material falling down or over that shaft or hole.

ACTIvE MINING AREAS:

The area of influence for heavy mobile equipment (self propelled, off highway mining and earthmoving equipment) actively performing mining work, including:

� excavation areas � dumping areas � production dozing areas � scraper circuits � other mining areas nominated by the

project manager.

juMp DuMpING:

Is a truck operating technique that involves reversing, jumping on the brakes hard while raising the hoist lever such that the rocking motion of the truck assists the hoist system in lifting an overload. This is an extremely dangerous technique that must not be used.

pIT WALL:

An individual wall section that is steeper than the repose or natural rill angle of the material.


Modify activities—eliminate the need for personnel to interact with operating mobile plant

Segregation of light vehicles from active operating areas with bunding

Establishment of exclusion zones and physical barriers to prevent unauthorised pedestrian access

Design areas to drive in and drive out to eliminate reversing

Designated light vehicle parking areas

Collision avoidance systems to slow/start plant movement

Maximise operator visibility (i.e. hazard detection systems and/or use of cameras or mirrors to provide operator with 360 degree visibility)

Traffic control plan

Plant shutdown procedure

Inspection and maintenance program

Communication protocol when entering operational areas

Mobile Equipment Recovery Permit

Limited reversing of haul trucks


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Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with mining operations are:

OvERLOADED TRuCk:

A haul truck is overloaded when the payload weight for a truck is greater than 120 per cent of the truck’s rated payload weight.

7


7. MINING OpERATIONS




� mobile assets being: — configured incorrectly before

use on each shift — not fit for purpose — inadequately maintained � uncontrolled movement of loads

when transporting or towing.

Within this Safety Essential, the term mobile assets refers to mobile plant and light vehicles.



8.1 Prior to acceptance into the business, a risk assessment shall be conducted on all mobile asset types to ensure they are fit for purpose and comply with:

� relevant legislation � Leighton Contractors and client

requirements.

8.2 Prior to acceptance of new mobile asset types onto site, a risk assessment shall be conducted to determine the operational application of those assets which includes:

� mobile asset suitability for site road design and construction

� mobile asset suitability for maintenance facilities

� operator visibility and blind spots � position and delineation of power

lines, overhead structures and other hazards within plant operating areas

� servicing and maintenance requirements.

8.3 Light vehicle selection shall be based on a risk assessment taking into account vehicle use and application, environment, client requirements, and the Australian New Car Assessment Program (ANCAP) rating.

The following minimum requirements apply to all new light vehicle purchases:

� Four wheel drive vehicles should only be purchased when off-road capability is required

� Vehicles should be selected to be suitable for the purpose they are intended for, with an aim to purchase suitable vehicles offering the highest ANCAP rating and maximise the number of ANCAP 5 rated vehicles purchased/used

� The following types of vehicles must be ANCAP 5 rated:

- light utility vehicles with ladder type chassis construction (e.g. Toyota Hilux, Ford Ranger, Isuzu DMAX)

- vehicles of monocoque construction (e.g. Holden Commodore, Ford Falcon and similar including utility variants)

- four wheel drive station wagon type vehicles with ladder type chassis construction (e.g. Toyota Prado, Nissan Patrol).

� Heavy utility vehicles with ladder type chassis construction (e.g. Toyota Landcruiser 76 series, Nissan Patrol utilities) may have an ANCAP 3 rating.

8.4 Vehicles transporting goods shall have their loads secured to prevent personal damage or loss of load. Lever type load binders (chain dogs) shall not be used.

8.5 There shall be a system in place to ensure all towing operations are carried out safely that includes:

� all trailers designed and inspected according to Australian Design Rules 62/01

� that rated safety chains are mechanically attached between the tow vehicle and the trailer

� an independent braking system if the trailer is over 750kg gross vehicle mass (GVM)

� authorisation of personnel carrying out towing operations

� that tow vehicles do not tow beyond their rated capacity.

8.6 There shall be a maintenance management plan for the maintenance, inspection and testing of mobile assets that includes:

� pre-start inspections � scheduled servicing � condition monitoring programs � testing programs � critical control systems.

8.7 Light vehicle pre-start inspections shall be undertaken for:

� vehicles in operational areas — before use on each shift

� vehicles not used in operational areas — at least weekly.

8.8 Defects that may affect the safe operation of the vehicle shall be identified, reported and the vehicle tagged out of service until the defects are rectified.

8.9 Modifications to mobile assets shall be subject to the modify fixed or mobile asset process (change management process).

8.10 Remote controlled and autonomous mobile assets shall have controls in place to safeguard the operator and other personnel in the vicinity of the work activity.

8.11 The operational and maintenance manuals shall be available on site.

8.12 For plant operating on coal stockpiles, fire suppression systems must be installed.

When those stockpiles contain a draw valve the plant must be fitted with:

� strengthened safety glass � an external emergency shutdown

positioned on the ripper box � a self rescuer and torch located within

the plant cab.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with safety when driving are:

LIGHT vEHICLE:

� can be registered for use on a public road

� has four or more wheels � seats a maximum of 12 adults

(including the driver) � where registered, could be legally

driven on a public roadway by a driver issued with a standard (basic level), public road driver’s licence

� does not exceed 4.5 tonnes gross vehicle mass (GVM).

MObILE pLANT:

A machine that is trackless, self propelled and controlled by an operator.

HEAvY MObILE pLANT:

Typically refers to a trackless mobile machine with a mass of greater than 32 tonnes.


Alternative means for travel in remote areas

Alternative means for travel for extended road journeys

Use of teleconference facilities

Fit for purpose vehicles

Cargo barriers

Vehicle specifications

Australian design rule compliant vehicles

Air bags and roll over protection

Use of in vehicle management system (IVMS) technology

Fatigue management business standard

Journey management plan

Modify fixed or mobile plant process (change management process)

Pre-start inspections

Gross vehicle mass (GVM) and load carrying capacity signage


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8. MObILE ASSETS

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� inadequate safeguarding of plant � personnel contacting moving plant

after safeguarding has been removed � plant being re-energised while work is

in progress � uncontrolled release of energy.



9.1 Prior to acceptance of plant, an asset inspection shall be conducted to ensure that:

� dangerous energies associated with the operation and maintenance of plant are identified

� safeguarding is in place and is serviceable

� positive isolation can be achieved.

9.2 Internally designed, modified or fabricated safeguarding shall:

� involve operations and maintenance personnel during the design and implementation stages

� follow the modify fixed or mobile plant process (change management process).

9.3 Safeguarding shall only be removed if the plant is isolated. If work must be undertaken on energised plant while safeguarding is removed, the live testing process shall be followed.

9.4 Manually operated rotating equipment shall be fitted with a fail to safe switch.

9.5 When safeguarding and or interlock systems are removed, access to that plant shall be restricted (e.g. using laser barricading, bunding, exclusion zones or spotters).

9.6 Falling object protection shall be in place under conveyor systems at designated vehicle and pedestrian travel ways.

9.7 Scheduled inspections shall be in place to ensure the presence and integrity of safeguarding.

9.8 An isolation process shall be developed based on a risk assessment that includes:

� live testing � all sources of dangerous energy � multiple isolation points and tasks � selection, inspection and

maintenance of isolation equipment � details of plant types that require

positive isolation.

9.9 Isolation shall provide personal protection and shall be achieved by the use of locking devices or:

� the establishment of a physical barrier � the depletion of stored energy, where

necessary.

9.10 An isolation permit shall be used for:

� group isolations � any isolation that is not a personal

isolation, and requires transfer between shifts or different workgroups.

9.11 A test to re-energise (test for dead) shall be conducted to confirm the plant is isolated.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with plant safeguarding and isolation of energy are:

pOSITIvE ISOLATION:

A method of isolation where there is zero potential of energy at the workplace and:

� all dangerous energy has been identified

� all dangerous energies are isolated at the source

� residual energy has been eliminated or controls are in place to prevent uncontrolled energy release.

ENERGISED pLANT (LIvE pLANT):

Equipment is energised at normal operating potential or energised to a potential from a source of supply not being its normal source of supply (e.g. a test instrument, generator or back feed).

MANuALLY OpERATED ROTATING EquIpMENT:

For example saws, lathes and drill presses.


Redesign equipment so safeguarding is not needed

Redesign plant/equipment to limit the need to isolate for routine tasks

Modify equipment so tasks can be conducted without removing guards

Physical barriers at areas that are energised or cannot be guarded

Interlocks and shutdown systems

Fail safe switches

Locking pins or mechanical stops where stored energy is present

Isolation and Live Work procedure and permit system

Inspection and maintenance program

Modify fixed or mobile plant process (change management)

Signage and tags

Test to re-energise (test for dead)


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9. pLANT SAFEGuARDING AND ISOLATION OF ENERGY




� personnel being struck by a falling tyre or rim

� personnel being struck by tyre handling equipment

� catastrophic tyre/rim failure or blow out � loss of wheel while vehicle is operating.



10.1 Personnel engaged in tyre changing activities shall be authorised, or working under the direct supervision of an authorised person.

10.2 All emergency response team members shall have participated in tyre and rim awareness training.

10.3 Risk assessments shall be conducted for all tyre management activities that include:

� assembling and changing tyres � suspected lightning or overhead

power line strikes.

10.4 The removal and fitting of tyres and/or the rim assemblies process shall incorporate:

� hard standing and lighting � jacking and stands � deflation � tooling � inflation.

10.5 There shall be a tyre management plan and a tyre and rim register that is current and readily available on site.

10.6 Hot work shall not be conducted on rims while tyres are inflated.

10.7 A hose with a minimum length of three metres shall be used to monitor and control tyre inflation. The gauge and shut off valve shall be positioned to enable the fitter to stand away from the hazard area.

10.8 While a tyre is supported by the tyre handler, the operator shall remain in the cab of the plant at all times.

10.9 During tyre inflation, the tyre handler shall be positioned to act as a barrier to mitigate the effects of a sudden energy release, and the operator shall not be in the cabin of the tyre handler.

10.10 When assembling a tyre off the machine, the tyre shall be kept in a horizontal orientation where possible.

10.11 There shall be a process to reduce the likelihood of hot tyres.

10.12 The process for tyre emergencies such as lightning strikes, contacting overhead power lines or hot tyres shall include their segregation for a minimum of 24 hours.

10.13 There shall be a process for the inspections of rims and rim components.

10.14 Where components are unfit for service, they shall be tagged and removed from service, and either repaired or scrapped in such a way that they cannot be reused.

10.15 There shall be a process to inspect and re-inflate under-inflated tyres when they are found to be more than 20 per cent under their normal inflation pressure.

10.16 Tyre handling attachments and manipulators shall have a maintenance, testing and inspection plan and a specific pre-start checklist.

10.17 Tyre handling attachments shall be fitted with:

� a fallback stop on the lift arm � an over-pressurisation alarm/relief

valve � a clearly marked maximum rated

capacity.

10.18 Tyre handlers shall have an engraved label with the maximum safe workload of the attachment and load chart displayed in the cabin.

10.19 Truck mounted tyre manipulators shall have a load chart that clearly displays the maximum rated capacity.

10.20 Multi-piece rims, less than 24 inches in diameter, shall be inflated in a cage.

10.21 There shall be a process for ensuring the correct tension is applied when wheel nuts are fitted.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with the management of tyres are:

HOT WORk:

� grinding � welding � thermal or oxygen cutting or heating � other related heat-producing or spark-

producing operations.


Replace rim assemblies with wheels

Segregation of hot tyres

Segregation of tyres suspected of electrical contact or lightning

Physical barriers to prevent access to tyre handling work areas

Tyre handling equipment

Fallback protection on tyre handling arms

Over-pressurisation alarm

Equipment support stands

3 metre hose and shut off valve for inflation

Cage for inflation

Locking system for wheel nuts

Tyre management plan and related procedures

Tyre and rim register

Inspection and maintenance program with tyres and rims

Certification of handling equipment

Label for safe work loads and maximum rated capacity


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10

24 | LEIGHTON CONTRACTORS

10. TYRES

MINING SAFETY ESSENTIALS | 25


This Mining Safety Essential applies to all Mining Division projects, activities, subcontractors and visitors when:

� there is the potential to fall from one level to another

� an object has the potential to fall and cause injury.


� persons falling from heights � persons being struck by falling

objects.

This Safety Essential does not apply to rope rescue performed by competent emergency response team members.



11.1 Work shall not be conducted above a height of two metres and/or within two metres of an unprotected edge, opening or fragile surface where there is potential to fall more than two metres without one or more of the following controls in place:

� temporary hand rails � hard barriers � working platforms and access

equipment (e.g. elevated work platforms, baskets, mancages and scaffolding); or, as a last resort

� personal fall protection equipment, provided the setup prevents a free fall (fall restraint system).

Personal fall arrest systems (e.g. that permit the user to free fall) cannot be used as a primary control.

11.2 Where a personal fall arrest system is required, a full body harness and self rescue leg strap shall be worn.

11.3 A working at heights process shall be developed based on a risk assessment identifying the working at heights activities conducted on site.

11.4 A Work at Heights permit is required where there is potential to fall two metres or more from or through a surface, and:

� there is no compliant fixed edge protection; and/or

� edge protection must be removed as part of the activity; and/or

� a fall restraint system is used as the primary control.

11.5 The Working at Heights permit shall include a rescue plan.

11.6 There shall be an inspection and maintenance process to ensure the structural integrity of:

� working at heights equipment � anchor points � access equipment � permanent access ways � hand rails on and for mobile and fixed

plant.

11.7 All working at heights equipment shall be:

� registered, inspected and tagged quarterly by a certified body

� stored and maintained in accordance with the manufacturer’s requirements

� inspected before and after use.

11.8 Personnel working in elevated work platforms or suspended work baskets (excluding scissor lifts) shall wear fall arrest equipment attached to certified anchor points.

11.9 During working at heights activities, elevated work platforms shall be protected from collision with barricading and not be operated outside their design parameters.

11.10 Exclusion zones shall be established using signage and barricades to identify areas where objects could fall and restrict access. If a total exclusion zone cannot be achieved then overhead protective structures shall be implemented.

11.11 Scaffold exceeding four metres in height shall:

� be designed and erected by a licensed scaffolder

� have completed scaffold tags attached

� be inspected at least every 30 days.

11.12 All personnel who conduct or approve work at height shall be authorised appropriately for their role.

11.13 Portable ladders (other than platform step ladders) shall only be used for access and not as work platforms.


Above the Line controls are the most effective methods of control and should always be exhausted before implementing Below the Line controls. Some examples of Above the Line controls associated with working at heights are:

pERSONAL FALL pROTECTION EquIpMENT INCLuDES:

� fall restraint systems � fall arrest systems.

LICENCE:


ExAMpLES OF AN AppROpRIATE WORkING pLATFORM:

� platform ladder � mobile scaffold.


Modify tasks to bring the job to the ground

Fixed walkways and access platforms

Scaffolding

Elevated work platforms (EWPs)

Suspended work baskets

Permanent/temporary handrails or fencing

Overhead protective structures (i.e. for travel ways under conveyors)

Physical barriers to restrict entry into exclusion zones

Kick boards

Lanyards for tools

Working at Heights procedure and permit

Equipment register

Inspection and testing of equipment

Personal fall protection/arrest system (with approved anchor points)


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11MINING SAFETY ESSENTIALS | 2726 | LEIGHTON CONTRACTORS

11. WORkING AT HEIGHTS

00 | LEIGHTON CONTRACTORSFor more information contact your site safety team. © Leighton Contractors Pty Limited July 2013

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