Applicable to Hillside and Bayside Aluminium

Task Based Risk Assessment

Process/ Task Assessed

Baking Furnace Fume Treatment Centre FTC2 Ducting

ASSESSMENT GROUP AND APPROVAL

NAME TITLE SIGNATURE DATE

Clive Winder Project Manager - Row Mac Engineering

Rashid Khan Site Supervisor - Row Mac Engineering

Chris Chetty Safety Officer / Safety Representative - Row Mac

Engineering
Vas Munien Maintenance Superintendant - Hilliside

REVIEW GROUP AND APPROVAL

NAME TITLE SIGNATURE DATE
Project Specialist

Projects Site Supervisor

Production Representative

Reduction HSE Specialist

Projects Superintendent

Production Superintendent

Production Superintendent

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
1.0 1
 RISK ASSESSMENT
TASK DESCRIPTION HAZARD DESCRIPTION HAZ # CONSEQUENCE DESCRIPTION CONSEQ IMPACT CURRENT CONTROLS Severity Likelihood Level Residual
(step by step) (What can go wrong?) (What are the after effects if the hazard occurs?) TYPE (What is currently in place to prevent the hazard from Level Risk
(H,S,E,C) occurring?) (Risk Level after you
implement controls)
dropdown calculated
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Access to the Hillside Plant and access Unfamiliar with Plant Risks 1 Injury to personnel and damage to Safety All personnel be site compliant.
to Carbon Plant Area including traffic, mobile vehicles, property Induction Training for all Personnel.
mobile equipment, heat, dust, All personnel shall be scheduled for Minor Rare Tolerable - Low

gases and molten materials. site access and all team members
known.
Not medically fit to access the site 2 Injury to personnel. Accelerated Health All personnel shall be medically fit
medical conditions / problems for site access. This shall be Minor Unlikely Tolerable - Low
checked prior to allowing them plant
access.
Planning No Method Statement, Risk 3 Injury to personnel and damage to Safety Method Statement, Risk Assessment
Assessment. Non compliance to the property shall be conducted prior to any
Construction Regulations. construction work. The vendor shall Minor Unlikely Tolerable - Low

comply with the Construction

Regulations
No awareness form plant personnel 4 Delays to planned work Environment Notifications to the plant Minor Rare Tolerable - Low

Transport of materials, equipment and Road accidents 5 Injury to personnel and damage to Safety The drive shall be possession of a
personnel to and out of site. properly valid driver’s license.
Vehicle to be roadworthy and in
good conditions. Daily checklist to
be completed and recorded Moderate Rare ALARP - Moderate
All vehicles on site must comply with
the FRC requirements
The driver shall adhere to traffic
signs
Equipment can fall off the vehicle 6 Injury to personnel and damage to Health Secure all loads properly. Do not
property transport personnel with equipment
together. All vehicles shall be FRC
compliant and shall be authorised to
access hillside site i.e. shall have a Minor Unlikely Tolerable - Low

green sticker. All loads on transport

to be strapped and secured with
rachet (load restraint).

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 Manually handling heavy 7 Body and back injuries. Pinch and Safety Ensure correct loads being lifted (all
equipment nip points loads will be assess by riggers first
prior to being off loaded if a crane is
required no persons will be allowed
to man handle it.). Use correct grip ALARP - Moderate
Moderate Unlikely
and correct body postures. Effective
communication skills shall be
practiced. Supervision at all times.

Access and route to offloading site
8 Poor communication on the off Safety Ensure that the driver know exactly
loading site where to offload the material and he
is fully aware of he route. Ensure
good communication between the Minor Possible ALARP - Moderate
machine operator and the vendor
site supervisor.

Off loading truck on site
Equipment falling off vehicle
9 injurie to personnel and damages to
property
Safety Park vehicle on level ground and
driver to shock tyre with wedges.
Ensure that the heavy load is still
strapped and secured and the rigger
has assess it prior to off loading. All
light loads are to be man handled
Minor Unlikely Tolerable - Low
(to be determined and assess by
rigger and recorded.) All heavy
loads to be rigged out of the truck
with a crane. Rigger to follow
rigging study.

Site Establishment and de- Unauthorised Access, No Permits to 10 Unauthorised Access and no Safety Acquire permit to work. Complete
establishment work authority to perform work JSA, site diary and workman's Moderate Unlikely ALARP - Moderate
declaration daily.
Uneven ground, sloppy surfaces 11 Tripping and falling. Body and back Safety Practise eyes on path at all times.
injuries Ensure correct PPE is used by all Minor Possible ALARP - Moderate
personnel
Improper handling of equipment 12 Body and back injuries. Damage to Safety Ensure correct loads being lifted.
equipment Use correct grip and correct body Minor Possible ALARP - Moderate
postures
Improper storage of all materials 13 Back injuries can occur. Equipment Safety Offload a safe distance from the
can crate unsafe hazards. Tripping can fall and can be damaged work area Minor Unlikely Tolerable - Low

hazards
Site identification and Barricading Unauthorised access onto the site. 14 Injury to personnel and damage to Safety Ensure visible barricading is used.
No signage to alert personnel properly All barricading shall be solid and Minor Unlikely Tolerable - Low
properly fixed to positions

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 No First Aider and first Aid box on
site
First Aid Box - None, inadequate,
expired components of the FA box
Toolbox Talk Toolbox Talks, irrelevant, none.
Poor communications
15 Unavailability when required. Can Health First Aider and First Aid box shall be
cause more damaged to injured available on site at all times during Minor Unlikely Tolerable - Low
personnel. Take to long to attend to the construction works
incident
16 Unavailability when required. Can Safety FA box shall be inspected by the
cause more damaged to injured Hillside Clinic. First Aid box shall be Minor Unlikely Tolerable - Low
personnel. Take to long to attend to sealed and shall only be opened in
incident the event of need
17 Irrelevant, none. poor Safety All toolbox talks shall be relevant to
understanding and language barrier the task to be performed daily.
Ensure all workman understand the
talk. Communicate and interpret in Moderate Unlikely ALARP - Moderate
different languages where possible.

Access to the Carbon Plant
Improper daily plan 18 Work team not aware of individuals Safety Discuss each team members
responsibilities can lead to poor site responsibilities daily Moderate Unlikely ALARP - Moderate
management that can result in
injuries
Environmental Hazards including 19 Heat exhaustion, hearing loss, Health Take regular breaks at the cool
heat, noise, dust foreign object in eye place, use correct PPE at all times, Minor Unlikely Tolerable - Low
use goggles and hearing protection

Interaction with vehicles, mobile
equipment and surface mobile
equipment
Unauthorised plant access. Entry to
other plant areas
20 Exposed in the line of fire for the
vehicles. Hit by the vehicle. Injuries
and fatalities
21 Multiple body injuries. Line of fire.
Not being aware of the risks in
Reduction and other areas of BHP
Billiton
Safety Stay away from the roads as much
as possible. Correct PPE with
reflectors or reflector vest shall be Minor Unlikely Tolerable - Low
worn at all time. Always remember
production vehicles have right of
way
Safety Always walk in designated areas. Do
not go to unauthorised areas of the
plant. Use only areas as discussed Minor Unlikely Tolerable - Low
and dedicated to access and leave
the construction site.

Use of equipment and tools.
Improper use of tools and 22 Injury to personnel and damage to Safety All tools shall be in a good
equipment property satisfactory working condition. All
tools shall be inspected daily and Moderate Unlikely ALARP - Moderate
the inspection log be kept on site.
All tools to be inspected by Hillside
and tagged.
Incompetence personnel using the 23 Injury to personnel and damage to Safety Competent personnel shall use the
hand tools property critical tools. Correct tools shall be Moderate Unlikely ALARP - Moderate
used correctly for all the tasks.

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 Damaged Tools and Equipment 24 Injury to personnel and damage to Safety All tools and equipment shall be
property inspected prior use. Electrical tools Moderate Unlikely ALARP - Moderate
shall be inspected and tagged by
Hillside
Tripping from equipment cables 25 Body injuries Safety Practise eyes on path at all times.
and extension cords Be observant and aware of the area
you are working in and the Moderate Unlikely ALARP - Moderate
surroundings. Supervision at all
times
Cutting of brackets with cutting torch. Open flame/Sparks 26 Sever bodily burns Safety Full PPE to be worn (Apron,
faceshields, long heat resistant
gloves, spats) when cutting. Only
competent person to use cutting
torch. Inspection on cylinders and
hose to be done before every use Minor Rare Tolerable - Low
for any leaks. Hot work permit to be
completed before performing job.
Flash back arresstors to be in place.
Fire watch to be available.

Secure pipes Nip and Pinch points 27 Laceration/Abrasion injuries to Safety Correct PPE to be worn (gloves). Moderate Rare ALARP - Moderate
hand/fingers Correct tools to be used.
Disconnecting fire line Pinch points 31 Laceration/Abrasion to Safety Wear correct gloves at all times. Use
hands/Fingers correct tools. Tools to be inspected Minor Unlikely Tolerable - Low

Personnel falling from heights
and recorded.
28 Serious body injuries. Fatality Safety Working at heights checklist to be
conducted before performing work.
Harness to be worn correctly and
trained. All safety harness to be Moderate Possible ALARP - High
inspected before use. Full PPE to be
worn including chin strap.

Falling/tools and objects falling
Improper use of hand tools
(spanners)
29 Serious body injuries. Fatality Safety Barricade the area at all time during
the project execution.Secure
tools/object with rope and prevent Minor Possible ALARP - Moderate
from falling. Only carry required
tools.
30 Injury to personnel and damage to Safety All tools shall be in a good
property satisfactory working condition. All
tools shall be inspected daily and
the inspection log be kept on site.

Installing temporary supports Pinch points 30 Laceration/abrasion to hands and Safety Wear correct PPE, gloves. Minor Possible ALARP - Moderate
fingers
Ergonomics 31 Back pain / dehydration Safety Take regular breaks at the cool
place, use correct PPE at all times, Minor Possible ALARP - Moderate
drink lots of water.

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 Damaged Tools and Equipment 32 Injury to personnel and damage to Safety All tools and equipment shall be
property inspected prior use. Electrical tools Moderate Unlikely ALARP - Moderate
shall be inspected and tagged by
Hillside
Slinging first ducting section Pinch points 33 Laceration/Abrasion to Safety Wear correct gloves at all times.
hands/Fingers Rigger to take control. Slings to be Minor Unlikely Tolerable - Low

inspected and recorded

Securing guide ropes Pinch points 33 Laceration/Abrasion to Safety Wear correct gloves at all times. Minor Unlikely Tolerable - Low
hands/Fingers Rigger to take control.
Breaking solidified pitch Pinch points 34 Laceration/abrasion to hands and Safety Wear correct PPE, gloves and face Minor Possible ALARP - Moderate
fingers shield.
Ergonomics 31 Back pain / dehydration Safety Take regular breaks at the cool
place, use correct PPE at all times, Minor Possible ALARP - Moderate
drink lots of water.
Damaged Tools and Equipment 32 Injury to personnel and damage to Safety All tools and equipment shall be
property inspected prior use. Supervison at Moderate Unlikely ALARP - Moderate
all times.
Removing bolts Pinch points 30 Laceration/abrasion to hands and Safety Wear correct PPE, gloves. Minor Possible ALARP - Moderate
fingers
Ergonomics 31 Back pain / dehydration Safety Take regular breaks at the cool
place, use correct PPE at all times, Minor Possible ALARP - Moderate
drink lots of water.
Damaged Tools and Equipment 32 Injury to personnel and damage to Safety All tools and equipment shall be
property inspected prior use. Supervison at Moderate Unlikely ALARP - Moderate
all times
Rigging out ducting Load falling/swinging/loading 35 Injuries to personnel & damages to Safety Rigger to be certified and
property. competent. Rigging equipment to be
certified with test certificates.
Barricade area where rigging is
taking place. Rigging study to be
done prior to any lifts and it is to be
Minor Unlikely Tolerable - Low
done by a competent rigger. Rigger
to take total control of rigging. No
man handling suspended load.
Guide ropes to be used. No persons
under suspended loads.

Heavy lifting/unauthorised rigging
36 Back injuries can occur. Equipment Safety Wear correct PPE, gloves. Rigger to
can fall and can be damaged take total control of rigging. No man
handling suspended load. Guide Minor Possible ALARP - Moderate
ropes to be used. No persons under
suspended loads.

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 Improper crane location 37 Damage to equipment and property. Safety Crane operator to be certified.
Competent rigger to ensure that
crane is in good working condition.
Only rigger must instruct the crane Minor Unlikely Tolerable - Low

operator to position the crane. Area

around rigging to be barricaded.

Removing slings
Rigging new ducting into position
Pinch points
Load falling/swinging/loading
38 Laceration/Abrasion to Safety Wear correct gloves at all times Minor Unlikely Tolerable - Low
hands/Fingers
39 Injuries to personnel & damages to Safety Rigger to be certified and
property. competent. Rigging equipment to be
certified with test certificates.
Barricade area where rigging is
taking place. Rigging study to be
done prior to any lifts and it is to be
done by a competent rigger. Rigger Minor Unlikely Tolerable - Low
to take total control of rigging.
Rigger to take total control of
rigging. No man handling suspended
load. Guide ropes to be used. No
persons under suspended loads.

Heavy lifting/unauthorised rigging
Improper crane location
40 Back injuries can occur. Equipment Safety Wear correct PPE, gloves. Rigger to
can fall and can be damaged take total control of rigging. No man
handling suspended load. Guide Minor Possible ALARP - Moderate
ropes to be used. No persons under
suspended loads.
41 Damage to equipment and property. Safety Crane operator to be certified.
Competent rigger to ensure that
crane is in good working condition.
Only rigger must instruct the crane Minor Unlikely Tolerable - Low

operator to position the crane. Area

around rigging to be barricaded.

Securing nuts and bolts Pinch points 42 Laceration/abrasion to hands and Safety Wear correct gloves at all times Minor Possible ALARP - Moderate
fingers
Removing slings Pinch points 43 Laceration/Abrasion to Safety Wear correct gloves at all times Minor Unlikely Tolerable - Low
hands/Fingers
Fitting and securing fire line Pinch points 44 Laceration/Abrasion to Safety Wear correct gloves at all times Minor Unlikely Tolerable - Low
hands/Fingers
Improper use of tools and 45 Injury to personnel and damage to Safety All tools shall be in a good
equipment property satisfactory working condition. All
tools shall be inspected daily and Moderate Unlikely ALARP - Moderate
the inspection log be kept on site.

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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Fitting and welding lagging rings Hot surfaces from welding 46 Bodily burns. Safety Full welding PPE to be worn. Screen
of where welding takes place.
Control access to and from site.
Only certified welder to do welding Minor Unlikely Tolerable - Low

at all times. hot work permit to be

completed before performing task.

Tripping hazard
Incorrect use of grinder/Sparks
47 Trip that may lead to injuries Safety Eyes on path. Report any unsafe
condition. Move electric cables out Moderate Unlikely ALARP - Moderate
of walk way and barricade.
48 Body injuries. Hands and fingers Safety Inspect grinder daily. Check for any
breakage of cutting and grinding
disc, inspect electrical cables. See if
safe guarding is in perfect order. Moderate Possible ALARP - High
Competent person to use grinder
and only 4 inch grinder to be used

Arc eyes. Grinding sparks
49 Eye irritations, loss of sight Health Use full PPE when grinding and use
welding helmet when welding.
Screen of where welding and Minor Possible ALARP - Moderate
grinding takes place and control
access to and from site.

Falling/tools and objects falling
50 Serious body injuries. Fatality Safety Working at heights permit to be
conducted before performing work.
Harness to be worn correctly and
trained. All safety harness to be
inspected before use. Full PPE to be Moderate Possible ALARP - High
worn including chin strap. Secure
tools/object with rope and prevent
from falling

Touch up painting Improper and incorrect painting 51 Respiratory problems Safety MSDS for paint shall be available
and be known. Use proper PPE, Low Unlikely Tolerable - Low

Gloves and wear respirator

Housekeeping No housekeeping 52 Unhealthy and unsafe environment Safety Ensure proper housekeeping ios Low Rare Tolerable - Low
completed
Response to Emergencies No response to emergencies 53 Injury to personnel, fatality Safety All personnel shall understand the
safety and emergency responses.
The nearest assembly point, Moderate Possible ALARP - High
emergency phone shall be identified
and known

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 RISK ASSESSMENT MITIGATION MEASURES
MITIGATION MEASURES HAZ HIERACHY OF CONTROL RESPONSIBLE PERSON(S) DUE DATE COMPLETED SIGNATURE
(What are we going to do now to reduce or control the risk?) #

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DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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 HIERACHY OF CONTROLS
LIKELIHOOD SEVERITY
Low (Level 1) Minor (Level 2) Moderate (Level 3) Major (Level 4) Critical (Level 5)
Intolerable - Intolerable - Intolerable - The hierarchy of controls 1. Eliminate 1. The complete elimination of
Almost ALARP - High ALARP - High
Extreme Extreme Extreme should be applied in the the hazard
Certain 10 30 100 300 1000 following order, individually
or in combination
2. Replacing the material or
process with a less hazardous one
2. Substitute
Intolerable - Intolerable -
ALARP - Moderate ALARP - High ALARP - High 3. Redesign 3. Redesign the equipment or work processes
Likely Extreme Extreme
3 9 30 90 300 4. Isolating the hazard by guarding or
4. Separate
enclosing it
Intolerable - Intolerable -
Tolerable - Low ALARP - Moderate ALARP - High
Possible Extreme Extreme 5. Administrate 5. Providing control such as training,
1 3 10 30 100 procedures, communication, etc.

Intolerable - 6. PPE 6. Use appropriate and properly fitted PPE

Tolerable - Low Tolerable - Low ALARP - Moderate ALARP - High where other controls are not practical
Unlikely Extreme
0.3 0.9 3 9 30
Tolerable - Low Tolerable - Low ALARP - Moderate ALARP - High ALARP - High
Rare
0.1 0.3 1 3 10  Eliminate, substitute and redesign are preferred control options as they remove the hazard so that other controls are redundant.
 Administrative and Personal Protective Equipment (PPE) provide interim controls in a planned programme to eliminate or reduce a particular risk or
may be used to supplement other control methods. However, they are not the preferred control measures.
YELLOW= LOW
GREEN = MODERATE
BLUE = HIGH
INTOLERABLE -
RED =
EXTREME

DOCUMENT NO. ISSUE DATE: 23 JAN 2012

FM100184 REVISION PAGE
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DOCUMENT NO. ISSUE DATE: 23 JAN 2012
FM100184 REVISION PAGE
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