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MANAGEMENT OF CIVIL WORKS

DOCUMENT: 18002-HSE-MG-030
405 MW dc SOLAR PV PLANT,SAKAKA- KSA

Owner / Client ACWA POWER

Owner’s Engineering

Principal contractor MAHINDRA SUSTEN

Name & Designation Signature Date Signed

Dibu. MK
Prepared by:
HSE Manager

A u t h o r i z e d b Muneer Nwairan
y: Project Director

Approved by ACWA POWER

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Document: 18002-HSE-MG-030-00
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DOCUMENT: 18002-HSE-MG-030
405 MW dc SOLAR PV PLANT,SAKAKA- KSA

Rev. No. Purpose of Issue Date Issued Remark

0 Initial release for approval 08/09/2018

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405 MW dc SOLAR PV PLANT,SAKAKA- KSA

Table of Contents

1. PURPOSE................................................................................................................................................5
2. SCOPE....................................................................................................................................................5
3. General information..............................................................................................................................5
3.1 References and definitions......................................................................................................................5
3.2 Responsibilities..................................................................................................................................6
3.2.1 General Responsibilities.................................................................................................................6
3.2.2 Specific Responsibilities:................................................................................................................6
4. Excavation Work....................................................................................................................................7
4.1 Control Elements:..............................................................................................................................7
4.2 DEVELOPMENT..................................................................................................................................7
4.2.1 Work in ditches and manholes......................................................................................................8
4.2.1.1 Preventive Measures.....................................................................................................................8
4.2.1.2 Other Measures...........................................................................................................................11
4.3 Trenches and Embankments............................................................................................................11
4.3.1 Preventive measures:..................................................................................................................11
4.4 Shoring of ditches:...........................................................................................................................12
5 Boring Drilling and Deep foundations..................................................................................................13
5.1 Development...................................................................................................................................13
5.1.1 Prefabricated Piles.......................................................................................................................14
5.1.1.1 Previous Tasks..............................................................................................................................14
5.1.1.2 Hoisting of Pile.............................................................................................................................15
5.1.1.3 Pile Driving...................................................................................................................................15
5.1.1.4 Heading of Pile.............................................................................................................................16
5.2 Piles concreted on-site....................................................................................................................16
5.2.1 Extraction and Displacement Piles...............................................................................................17
5.2.2 Drilling..........................................................................................................................................17
5.2.3 Continuous Flight Augers.............................................................................................................19
6 Form work and Concrete work............................................................................................................19
6.1 Control Elements:............................................................................................................................19
6.2 Development...................................................................................................................................20
6.3 Formwork........................................................................................................................................20
6.4 Framework.......................................................................................................................................21
6.5 Manipulation of Concrete................................................................................................................22

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6.5.1 Pumping Operations....................................................................................................................22


6.5.2 Pouring operations using a chute................................................................................................23
6.5.3 Pouring Operations using Buckets and Skips...............................................................................23
6.5.4 Portable cement mixers...............................................................................................................23
6.6 Machinery........................................................................................................................................23
6.6.1 General Rules...............................................................................................................................24
6.6.2 Rules for use and maintenance....................................................................................................25
6.7 Auxiliary Equipment.........................................................................................................................26
6.7.1 Concrete Vibrator........................................................................................................................26
6.7.2 Bucket..........................................................................................................................................27
7 Related documents..............................................................................................................................27

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1. PURPOSE
The purpose of this procedure is to establish the minimum safety conditions for carrying out Civil works

2. SCOPE

This procedure applies to all works development during the construction and commission to 405 MW dc
SOLAR PV project.

Apply to all companies hired to perform works and services on the Project, even when they have been
contracted by another company, as long as they are coordinated and supervised by the responsible of the
organisation unit or project.

3. GENERAL INFORMATION

3.1 REFERENCES AND DEFINITIONS

1. Earthworks: Set of works carried out on the terrain to modify its surface, preparing it for
construction and adapting it to its definitive shape. It covers soil back and fill.

2. Excavation: Extraction of earth in localised areas of terrain.

3. Ditches and Manholes: A ditch is defined as a long, narrow excavation and a manhole as a
vertical or inclined excavation whose dimensions of depth exceed length and width. Both are
made with manual or mechanical equipment and, moreover, must fulfil the following
characteristics: Width/Diameter ≤ 2 m, Depth ≤ 7 m, groundwater level lower than depth or
lowered and not including rocky, soft or expansive terrain

4. Trench: Open-air excavation made with manual and/or mechanical equipment which, along its
perimeter, remains below ground level. Excluded are grounds marked for explosives, slurries or
mud. When the diameter of the excavation is ≤ 2 m it is considered a ditch.

5. Embankment: Raised sloping bank of earth.


6. Shoring Systems Set of prefabricated components used to support the vertical walls of ditches.

7. Deep Foundation: Consists of concreting, underground and to varying depths, "columns" to


serve, generally, to support foundations.

8. Prefabricated Piles: This type of pile is driven by striking, with mechanical or hydraulic
machinery. They may be of reinforced or pressurised concrete, wood or metal, with a round or
polygonal section (usually square or hexagonal) protected at the tip by a metal piece to allow
striking. They can reach any depth by splicing (metallic tongue and groove joint etc.).

9. Piles fabricated on-site: There are many different and varied systems for fabricating piles, but in
general they can be extraction, displacement or continuous flight augers, among others.

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o For Extraction Piles, first the ground is extracted and then the rebar and the concrete is
lowered into place. Diameters range from 35 to 200 cm with depths of up to 45 metres.
o For displacement piles the closed tubing is struck on the lower, displacing the earth (it is
not extracted) and later the rebar and concrete is later set in place. Used for small-
diameter piles
o In the case of Continuous Flight Auger piles their full depth is drilled and once the
required depth is reached, the drill is extracted while simultaneously concrete is
pumped through the hollow auger, followed by the lowering of the rebar. Diameters
range from between 35 and 120cm with depths of up to 32 metres

10.Concrete: Concrete is a mixture of cement, water, coarse aggregate, fine aggregate and,
eventually, additional products that, as they set and harden, acquire the desired resistance.

11.Formwork: Formwork assembly is the joining of different single panels which are modulated
until the desired form is achieved, both for height and length, including working platforms,
accesses, etc. Units included in formworks are: assembly, transportation and placement.
Framework Refers to the steel bars and girders placed inside the concrete mass to combine with
it and support the loads necessary, especially tensile stress. The preparation and placement of
frames is an operation to be carried out manually and by specialized personnel. It comprises
straightening, cutting, flexing and placing operations

3.2 RESPONSIBILITIES

3.2.1 GENERAL RESPONSIBILITIES

All persons involved in the project, work or service, including supervisory staff from both EPC and
Subcontractors, must continuously contribute to ensure strict monitoring of that established in this guide
and in any other related guide, in order to ensure the adequate administration of risks in all areas under
their responsibility.

3.2.2 SPECIFIC RESPONSIBILITIES:

12.Project Director/ Construction Manager: Provide the necessary elements and support to
facilitate communication, implementation and monitoring of that established in the project for
which they are responsible.
13.Execution Staff: Guarantee monitoring of that established in this guide for all areas under their
responsibility.
14.H&S Manager: The H&S Manager will be responsible for the training of relevant persons
(Contractor Safety Supervisors and all staff), implementation and application of this guide on all
project fronts and will verify the monitoring thereof.
15.Subcontractor Safety Supervisors: Responsible for training in the contents of this guide to all
supervision staff of the respective companies, for the purpose of ensuring that monitoring of
compliance with this guide and any other related guide at all levels of their organisation.
16.Operators and Riggers: Follow the provisions of this procedure and other related procedures.
17.Workers: Take the pertinent safety measures for the work to be performed

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4. EXCAVATION WORK

4.1 CONTROL ELEMENTS:


Before initiating any excavation work, the direct supervisor of the work must complete the following
activities in the order they are listed:
18.They shall handle the corresponding permits to work in accordance with 18002-HSE-MG-017-0
Permit to work management.
19.It must be verified that the signalling of the area is in accordance with 18002-HSE-MG-013-00
HSE Signposting
20.It must be verified that the machinery, work equipment and access/exit elements and crossings
to be used on the excavation are in good conditions.
Prior to opening an excavation, no objection certificates (NOC) shall be obtained from all concerned
authorities having jurisdiction of excavation. Permits shall be in compliance with the actual conditions and
in case that there are any differences; the concerned authorities shall be consulted before the start of the
excavation.

4.2 DEVELOPMENT

In activities based on earthworks and infrastructural work (sanitation, supply, etc.) excavation works
represent a high percentage of serious and fatal accidents, as one of the major causes of trapping or
burying accidents caused by subsidence and landslides.
Before initiating any excavation work, the direct supervisor of the work must complete the following
activities in the order they are listed:
21.They must obtain information relating to the presence of underground lines and/or installations
that may imply additional risks.
22.A meeting shall be held with staff that is to perform same to communicate the risks identified
and the emergency measures necessary. All persons working in the vicinity of the operations to
be carried out will also be informed.
23.It must be verified that all persons involved in the operation have the necessary personal
protective equipment.
24.You must ensure that additional necessary elements (lighting, auxiliary equipment, etc.) are in
place.
Moreover, you must:
25.Know in advance the physics and mechanics of the terrain (stratification, fissures, etc.).
26.If necessary commission a Geological and/or Geotechnical Study in advance to determine the
appropriate method of protection for the interior of excavations.
27.In the case of not shoring and deciding to proceed with embankments, you must know:

o The degree of seismic activity of the location of the cutting.


o The floors and sections of the provisional cuts for the project.
o The type, location, depth and dimensions of nearby foundations and roadways that are
of an equal or distance or less than twice the depth of the provisional cut.

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o The evaluation of the compressive stress to the terrain transmitted by nearby mounted
or deeper foundations.
o The groundwater level.
o The permeability and disagreeability in water.
o The degree of dryness.
o The apparent specific gravity.
o The simple stress resistance of unaltered samples.
o The characteristics of cuts of terrain based on the experience in the location of the
works.

28.Have information from public bodies and utility companies to allow us to locate conductions
and channellings for water, gas, telephone lines, sanitation and electricity and to determine the
exact method and the most appropriate protection systems.
29.Anticipate static and dynamic overload on terrain close to any buildings(if persist), machines,
storage of materials and roadways or streets.
30.Plan shoring and supports taking into account the proximity of neighbouring buildings,
machines, storage of materials, roadways and streets.
31.Always remember that subsidence and landslides can occur even in rocky terrain.
32.Verify excavations daily (regardless of type; ditch, manhole or trench), embankments, especially
if:
o There are lengthy interruptions
o Situations of ice, defrost, rain etc.
33.If, during excavation, any unexpected anomaly arises, work must be stopped, and Site
Management must be informed.
If it has been established that the geotechnical study is not obligatory, whether because the site has no
project or for any other reason and this, effectively, is not carried out, other favourable measures must be
taken from the perspective of prevention based on professional judgement.

4.2.1 WORK IN DITCHES AND MANHOLES

This type of excavation is associated with the type of underground line work that covers the set of
infrastructural work on supply, sanitation and channelling networks.

4.2.1.1 PREVENTIVE MEASURES


Design
In general, consider as dangerous any excavation that, in loose ground, reaches a depth of 0.80 m and
1.30 m in ground with bad cohesion.
For each depth and phase of work that requires access for operators to the ditch or manhole, it must
provide for their movement between the shores and other work, of a circle with diameter ≥ 0,80 m.
On ground with good cohesion and without requests for foundation work or proximity to a roadway (or
similar element), where H 1,25 m, vertical cutting can be performed without shoring design by a

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professional organization or by using an open excavation that is approved by the Specialized Department.
For greater depths, shoring or the construction of an appropriate embankment is required. The maximum
angles to be considered for these shores are:
34.40º on inconsistent or loose ground
35.60º on ground with good cohesion
36.80º on rocky ground
On loose ground not reaching this depth, or ground with good cohesion with requests for foundation
work or close to a roadway, adequate shoring or embankment must be applied to the walls of the ditch
less that those above.
Shoring can be done via terraced berms, with plateaus of no less than 0.65 m and slopes no greater than
1.30 m in excavations with sloped ground at angles between 60º and 90º for an admissible height based
on the specific apparent gravity of the ground and the simple resistance of same. Maximum height in
vertical cuts, free of loads, for different specific ground weights.

It is also advisable to shore when embankments are more accentuated that would be ideal for the
characteristics of the ground, or where berms do not meet the conditions provided. (See Shoring System
Files addendum to this Procedure).
Ditch Access and Crossing
If access is by a hand ladder, these must be free obstacles at both the upper and lowers steps. The upper
section must be anchored, and they must protrude at least 1 m above the ditch. On the lower section
they must be supported by a surface that acts as a load distributor, to avoid and destabilizing or incline.
An access and exit ladder must be provided for every 6 workers. Ladders must fulfil these requirements:
37.They cannot be made on-site.
38.They must be fixed to a point beyond the edge of the excavation to prevent their moving.
39.Ditches of more than 1.20 m in depth must have a security exit such as a ramp or perhaps a
ladder within a minimum of 8 m of every worker.
Where ditch crossings for pedestrians or vehicles are possible, walkways with handrails on both sides
must be installed; the width of these walkways will be a minimum of 60 cm for pedestrians and a
minimum of 2 m for vehicle while the length must be equivalent to 1.5 times the total width of the ditch
Where made of wood, they must be 1 ½ inches thick, preferably single piece and with two battens on the
reverse side over the whole length to prevent breaking.
These elements must be fixed to prevent any movement or sliding. Crossing elements must be laid no
more than 10 metres from each other.

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Where they are to remain in place for more than 5 days, crossing elements must be fitted with handrails.
The evacuation route in a trench to the exit must be free of all obstacles.
Signalling and Protection
For H ≥ 2 M, the borders of the ditch will be protected with a regulation handrail of 1 m in height which
will run parallel to the ditch throughout its course. The handrail will have a 1 m break for pedestrian
crossings and 2 m for vehicle.
For H < 2 M, the ditch will be signalled and delimited by signalling tape from a sufficient distance.
Distances for accumulation of material and vehicle traffic
Avoid the accumulation of excavated material and excavation equipment beside the edge of the ditch,
take precautions to prevent the collapse of walls and material from falling.
As a general rule, the distance at which material can be deposited from ditches shall be 1.5 times the
depth of the ditch, with a recommended minimum distance of 2 m to eliminate the pressures of the ditch
walls. In the case of vehicles circulating at close proximity, this distance should be increased to twice the
depth of the excavation with a minimum recommended distance of 4 metres.
When vehicles circulate at normal speeds, the buffer areas will be increased in this direction to twice the
height and no less than 4 m when speed reduction signals are installed.
Lighting
Whenever pedestrian or vehicle traffic may occur near ditches during night hours or in case of poor
visibility, beacons shall be used as signs.
Whenever pedestrian or vehicle traffic may occur, fences shall be illuminated every 10 m with portable
lamps.
If the inside needs to be illuminated, external lighting towers shall be used.
If portable lamps are used inside, these lamps must be powered at 24 V.
Uncovered excavations

Excavations shall be uncovered for as short a period as possible in order to avoid risk of slides caused by
weathering, considering the following factors:
40.When excavations are to be uncovered for over 5 days, the installation of reinforcing steel and
false work as soon as possible shall be considered a priority task.
41.When ditches are to be uncovered for over 5 days, adequate protections must be placed.
42.Still pillars for towers or pillars which are to be uncovered must be protected with appropriate
signals and covered with wood planks to prevent persons or animals to fall in them.
Excavations or ditches crossing with subterranean public supply line

It is not allowed to use any machine on an excavation which overlaps any subterranean line, regardless of
whether it is in use or not. These excavations must be carried out using manual tools.
A safety distance of 80 cm over any identified public supply line is recommended all along the excavation.
Whenever it becomes necessary to work close to a public supply line, support wedges must be used in
order to prevent it from collapsing under its own weight.

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Floods

In periods of high rainfall, the ditch and the piping system shall be revised before the start of works.
If there is risk of flooding, bilge pumps may be installed in order to be able to quickly remove water.

4.2.1.2 OTHER MEASURES

Ditches will be submitted to daily inspecting and, when a sign of danger is detected, works will be
suspended and adequate preventive measures will be taken, such as diminishing wall slope.
Remove or reduce as much as possible making noises inside the ditch, since they may interfere with the
implemented alarm system.
For > 1.30 m, provided there are operators inside the ditch, one team will remain outside the ditch.
Operators working inside the ditches must be sufficiently trained and informed.
If subcontractors are hired for these tasks, it must be ascertained that they comply with the security
measures.
Work at different levels inside the ditch and in the vicinity of machinery is not allowed.
There must be sufficient manual means (shovels) in the area to carry out a rescue in the case a worker is
buried as a result of an accident. Mechanical means must never be used in rescue operations.

4.3 TRENCHES AND EMBANKMENTS

Civil works require extensive earthworks, such as excavations, embankments and trenches, from which
the following main hazards arise:
43.Those risks associated to the use of machinery.
44.Slips, trips and falls
45.Workers being buried as a result of an accident while working on or passing nearby the top of
embankments and especially when building foundations, drainages and waterproofing of walls
and working close to them.
Therefore, it is necessary to guarantee:
46.Embankment stability by guniting or by any other contention method.
47.Protection of embankment top areas.
48.Access conditioning
49.Avoidance of or protection for works at different levels.

4.3.1 PREVENTIVE MEASURES:

Trench design

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Trenches may be carried out either constructing a retaining structure along its walls or not, depending on
the type of ground, the loads and stresses the trench shall be submitted to, the existence of buildings
nearby, etc.
Internal protections without previous retaining structure
Ideally, natural embankments will be carried out. However, in a trench box excavation at the depths used
nowadays, this has proved wishful thinking. Therefore, when it is not possible to build natural
embankments, it will be necessary to carry out the following actions:
50.Shoring and timbering This system is normally used as needed without prior planning in vertical
or otherwise inadequate embankments.
51.Foundation trenches and supports A combination of the two previous systems and based on an
alternative process, optimal for earth control and contention on moderate depth excavations on
acceptable ground.
52.Slurry walls
Internal protection of excavations
In order to prevent falls to the bottom, trench or trench box tops shall be protected by means of:
53.All trenches will be protected with orange mesh or similar
54.Fixed fences with railings and kickplates in areas with high traffic
55.Signs and buoying outside work or transit areas.

Barricade system

Barricades can be classified into two groups  a) Indicative Barricades and b) Protective Barricades.
Safety tape strings along with rope(Manila), portable steel frame barricades, portable road barriers like
cones, Jessy barrier, drums and road runners form the group of indicative barricades.
MS Pipe, Rail guard, concrete guards, steel frame barricades grouted firmly onto the ground, permanent
fencing etc. form the group of protective barricades.

Type of barricade is to be selected depending upon the requirements, site location challenges (vehicle
movement, depth & width) or any statutory provision.

Trenches which close to Main internal road, and on other areas where depth which having more than
0.5m should be protected with protective types of barricade system along with safety sign positing and
automated flash blinking lights on the turns, corners of the roads.
Trenches with less than depth of 0.5 m and which does not raise any potential risk to vehicle movement,
work force and animal’s, protection should be done with indicative barricade system.

Trenches which having bunded soil on the edges/close to excavation, barricade can be done with
indicative barricade system like with manila rope along with barrication tape stringing with safety sign
posting. (Again these point depend on Method statement, if MS stated to remove the soil on the same
time of excavation then both side of excavation will be open and barricade should be provided
accordingly).

4.4 SHORING OF DITCHES:

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Dimensions of ditches must be designed considering maximum foreseeable loads in the worst-case
scenario.
Metal shores must be certified and an instruction manual in English including all the necessary
information about their safe use, assembly and disassembly must be provided with them.
Shores will be inspected at the beginning of each work day. The utmost care shall be taken after the
works have been interrupted for over a day or in rain or frost conditions.
Shores must be 20 cm over the trench edge so they can function as kickplates and prevent objects and
materials from falling into the ditch.
In general, shores will only be fully or partly removed when they are no longer needed and they will be
disassembled by horizontal levels, starting by the ditch bottom.
It is forbidden to access or exit the ditch by climbing up or down shores.

5 BORING DRILLING AND DEEP FOUNDATIONS

5.1 DEVELOPMENT

Among the machinery for foundation we have those formed by coupling of a base crane, special drilling
equipment, those designed specifically for drilling (with orientable guide), pile drivers used only for
driving prefabricated piles or tubing and special equipment for micro piles for rotation drilling.
A great number of the accidents that occur in these foundation works occur in the assembly, disassembly
and setting of these machines. The main causes are usually that these are not fitted with adequate safety
elements or that operators do not employ the required protection measures.
All personnel carrying out assembly works must be specialized in that and must not enlist assistants
without adequate preparation.
It is prohibited to perform work simultaneously on different levels and to have operators in the vicinity of
the machinery. Assemblers must be provided with a tool belt.
The laying of cables, hoists, guides etc. can cause instances of trapping. These may be very dangerous
when working with auxiliary motorised equipment. Thus it is absolutely essential that there clearly
defined rules for all operations to be carried out in assembly.
In the upper sections of turrets where work requiring effort has to be carried out with a certain degree of
frequency and with room to manoeuvre, a platform fitted with handrail and baseboard will be made
available.
In the assembly and setting of rotation motors, in the lower part, work platforms should be supported in
the ground or well coupled to the machine and always with the required handrails, baseboards and
convenient access.
The different coupling elements of the equipment, such as drills, vibrators etc., when not in use, must be
placed in adequate areas, secured against movement and not left carelessly around the site.
For pile drivers, whether gas oil, compressed air, hydraulic etc., we must bear in mind that:

56.The maces must be always be lowered between guides, and must be checked and greased daily.
57.The handling of pile drivers must be assigned to competent personnel.
58.Pile drivers must be secured on large, solid sleepers.
59.If the base is not sufficient to support the pile driver, it must be strutted appropriately.

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60.When several pile drivers are installed together, a space of the 1 and a half times the length of
the longest must be observed between them.
61.The motors must be protected with adequate casing to prevent trappings.

5.1.1 PREFABRICATED PILES

1.- Start hoisting of pile 2.- Lifting of pile 3.- Fixing head of pile 4.- Release of clamp and raising of
hammer

5.- Presentation manoeuvre 6.- Presentation and positioning of 7.- Hammer Driving 8.- Completion of driving
Driver

5.1.1.1 PREVIOUS TASKS

Preparation of work area

62.To Delimitation and signalling of site, loading and unloading area, storage of material and
positioning of equipment.

Loading and unloading of material and machinery

63.Reception of material by flatbed trucks.


64.Unloading of material with cranes and appropriate hoisting elements.

Assembly and disassembly of equipment


65.Preparation of equipment for functioning, checking of cabling, hoses, valves, hoisting or
lowering of pole.
66.Hoisting of pole, this will be lifted until it reaches the vertical position through the action of the
hydraulics located in the machine control panel.
67.These tasks are to be performed by trained, qualified personnel

Preventive Measures

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68.Do not at any time position yourself under suspended loads.


69.Respect the maximum load of lifting apparatus.
70.Periodically inspect all lifting elements (cables, slings, poles, hooks...).
71.Use the appropriate hoisting points to load the machine.
72.Ensure that you are in the crane operator's view at all times.
73.Once the pile is attached, the assistant must position themselves in a secure location to avoid
becoming trapped or being struck by the piles.
74.Always transport the load using guide ropes (never with the hands).
75.Use gloves, hard hat and safety footwear when handling heavy tools and materials.
76.Temporary storage areas must be kept clear of any materials that may pose an obstacle to their
collection.

5.1.1.2 HOISTING OF PILE

For attaching the pile to the machine, use the winch hook.
Once the chain is attached to the pile and lightly hoisted, put a security sling in pace.
Once the safety devices are checked, proceed with the hoisting of the pile as far as a vertical position
within the clamp when it is in an appropriate position to begin the driving process. This operation is called
presentation of the pile.

Preventive Measures

77.Perfect coordination between the operator and the assistants ensuring no movement is made
until indicated.
78.Trained and qualified personnel, limited to the number strictly necessary for the guiding and
placement of the pile.
79.Use the correct tools for each task and keep them in good condition.
80.Follow the procedures and do not rush.
81.There must be good coordination between the operator and the assistant
82.Before hoisting, a visual inspection of the piles must be performed to detect any loose objects
that may have come loose.
83.Nobody may position themselves within the operating range of the pile so as to avoid any falling
particles.
84.Never position yourself under a suspended load.
85.Check that hoisting elements are in good condition.
86.It is prohibited to leave the pile suspended.
87.Ensure that he load is correctly fixed and that elevation hooks have their safety closed.
88.You must place a sling alongside the security chain (comprised of a cable with hook ends and a
safety loop) to prevent the pile falling in the case of the chain breaking.
89.During positioning and attachment of the pile, ensure that your feet are well outside its reach

5.1.1.3 PILE DRIVING

The hammer must strike the pile in such a way so that it is inserted into the ground gradually.
The striking or insertion into the ground until resistance is met or until the depth established by the
project is reached.

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When checking for resistance , a test is performed in the last three of ten blows each.
From time to time it is necessary to splice the two piles before resistance is met.

Preventive Measures

90.Never place your hands between joints when forming a union with the following section or
when placing connection spindles, so as not to strike with the mace.
91.When changing the wedge, check that the hammer is resting on the safety support bolts and
that the machine is stopped.
92.The assistant must remain a safe distance from the machine and in view of the operator.
93.Never enter the driving area without the permission of the operator.
94.There must be good coordination between the operator and the assistant
95.All measurement with the machine stopped.

5.1.1.4 HEADING OF PILE

After driving, the heads of the piles are to be demolished, until they reach the desired level.
For breaking concrete, perform automatically with a hydraulic cutter transported by crane.

Preventive Measures

96.Once the cutter is in place on the pile, stay clear while concrete cutting is in progress.
97.Use safety glasses when cutting the pile with the radial saw.
98.Guide slowly, supported by the four suspension chains.
99.Never position yourself under the cutter and arm of the machine.
100. Check that suspension hooks are in place and tightly secured.
101. Never leave the machine unattended with the motor running
102. The welder must use the appropriate PPE (mask, apron, gloves...).
103. Do not use the high visibility vest when cutting.

5.2 PILES CONCRETED ON-SITE

Preparation of work platform

104. Delimitation and signalling of site, loading and unloading area, storage of material and
positioning of equipment.
105. Preparation of platform which must be: stable, horizontal and on compact ground with
no sinking or protuberance.

Loading and unloading of material and machinery

106. Reception of material on flatbed trucks.


107. Unloading of material with cranes and appropriate hoisting elements.

Assembly and disassembly of equipment

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108. Preparation of equipment for functioning (checking of cabling, hoses, valves, hoisting or
lowering of pole...).
Preventive Measures

109. Always transport the load using guide ropes (never with the hands).
110. Use gloves, hard hat and safety footwear when handling heavy tools and materials.
111. Do not drag loads
112. Never remain under a suspended load.
113. Respect the maximum load of lifting equipment.
114. Periodically inspect all lifting elements (cables, slings, poles, hooks...).
115. Use the appropriate hoisting points to load the machine.
116. For work at heights greater than 1.8 m with no security perimeter the use of a safety
harness anchored to a lifeline is obligatory.
117. Always ascend to and descend from the cabin facing forwards and at the points
designated.

5.2.1 EXTRACTION AND DISPLACEMENT PILES

1.- Drilling
2.- Cleaning of end, where necessary
3.- Placement of Pier/VP
4.- Concreting with tremie pipe/Chute
5.- Finished pile

5.2.2 DRILLING

On-site piles with dry rotation

Drilling performed on compact ground with no water using rotary drilling equipment with screws without
collapsing ground.

On-site piles with bentonite slurry

Drilling performed using bentonite slurry, for its stabilizing properties, on non-compact ground with
water.
This type of deep foundation requires the construction of a slurry plant for manufacture and recycling.

Piles with recoverable lining

Drilling performed within a metallic lining which is inserted directly by rotation with the machine itself, on
non-compact ground.

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Preventive Measures

118. Use mask when breaking and pouring sacks of bentonite


119. Maintain a safe distance during drilling and when removing the rotary.
120. When measuring the hole the worker must be fixed to a fixed, secure point.
121. Protect the drilling area at all times.
122. Do not raise the rotary during change.
123. The desander must have a well anchored, secure access ladder.
124. Platforms must have handrails.
125. Tubing piles must be protected with lining which should protrude a minimum of 90 cm.
126. Never position yourself under a suspended load.
127. Check that hoisting elements are in good condition.
128. Use the correct tools for each task and keep them in good condition.
129. Stay clear of the operating range of the machine and protect the back part with handrails
130. Perfect coordination between the operator and assistants, with visual contact at all times.
131. Only clean loose earth once the drilling process has been completed, never during.

Concreting

132. Placing of Pier and align by zig and Total station


133. Pouring of concrete by chute or hose

You must bear in mind:

134. When you work with bentonite slurry, it is important that concreting is always done
under the slurry so that when it is poured, the slurry rises and can be extracted by pumping.
135. When working with recoverable linings, they must be extracted partially as the concrete
advance

Preventive Measures

136. Clean the tremie pipe correctly after use


137. Use safety glasses to prevent splashing into the eye when concreting.
138. Do not touch concrete with your hands. Always use safety gloves.
139. Do not secure the funnel or chute of the truck with your hands.
140. Lower and raise the tremie pipe vertically, avoiding abrupt movements and collisions
against rebars installed.
141. Wait until the truck is completely stopped before deploying the chute.
142. Never remain under suspended loads (tremie pipe)
143. The extraction of the pipe is only performed when personnel and the truck are at a safe
distance.
144. Maintain the work platform clean of water and loose material from drilling, diverting
these materials to a decanting pool

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5.2.3 CONTINUOUS FLIGHT AUGERS

Dry Extraction Piles


1.- Drilling
2.- Concreting and Simultaneous Earth Extraction
3.- Removal of Earth
4.- Lowering of Pier

Drilling

The drill is inserted into the ground in one single continuous operation, until the desired depth is reached

Preventive Measures

145. Use the correct tools for each task and keep them in good condition.
146. Perfect coordination between the operator and assistants in auxiliary operations.
147. Clean loose materials when drilling is completed and never during.
148. Use ropes to separate concrete and/or hydraulic hoses.

Concreting

Once drilling has been completed, install vertical post and concrete is poured through the concrete chute

Preventive Measures

149. Use safety glasses to avoid splashing.


150. Do not position yourself within the operating range of the drilling machine when the drill
is being extracted
151. Do not touch concrete with your hands and always use protective gloves.
152. Do not climb into the hopper of the concrete pump.
153. Do not remove the concreting hose without first checking for the absence of pressure.
154. Wait until the truck is completely stopped before deploying the chute.
155. Keep work areas clean and ordered

6 FORM WORK AND CONCRETE WORK

6.1 CONTROL ELEMENTS:

156. The kind of formwork must be defined based on the type of structure. Likewise, the
formwork must be solid enough to support, without substantial deformations, the concrete load
it contains.
157. A safe access to the work area must be defined.

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158. Formworks must be stored in an ordered manner, always horizontal in appropriate areas,
clear of transit areas.
159. The conditions of the formwork panels, associated collective protections and all auxiliary
elements for the assembly must be verified.
160. Armour kits shall be secured for hoisting in such a way to make it possible for it to slip;
specifically, guide rope kits will be fitted.
161. Concrete works will not commence until the work area is clear of any objects relating to
another activity, and the installation of auxiliary equipment, such as pumps and vibrators, are
correctly installed and functioning.
162. Auxiliary equipment must be inspected frequently, in particular ensuring that electrical
components are correctly isolated and pipes are clear of cement and mortar.
163. The pouring of concrete and mortar shall be done from a height, low enough to ensure
there is no unexpected splattering.
164. Work carried out in confined spaces, subject to high thermal gradients due to settling
phenomena must be provided with an oversized clean air supply, to maintain the temperature
and allow the work to be carried out in adequate conditions.

6.2 DEVELOPMENT
Concreting for reinforced, mass or prestressed concrete structures includes the operations of:
165. Supply of concrete
166. Testing of plasticity of concrete
167. Preparation of formwork.
168. Placement of frames (in the case of reinforced framework)
169. Pouring and compacting of concrete.
170. Curing of concrete
The pouring of concrete can be varied, fundamentally involving:
171. Direct concreting from cement mixing truck.
172. The use of tower cranes and mobile cranes.
173. Pumping using a concrete pump.

6.3 FORMWORK
Formworks may fall into two categories: "traditional" (usually wooden) and "prefabricated" (metallic or
wooden).
Typology:
174. Horizontal, used for beam formwork of beams and slabs.
175. Vertical, for formwork, walls, pillars, piles, etc.
The most important constituent elements are:
a) “Traditional” (planks, boards, panels and others).
b) Prefabricated (panel, clamps, stabilizers, work brackets and hoisting grippers).
As many operations as possible must be performed on ground level, including the assembly of working
platforms, before the placement in-situ of the formwork.

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Assembly, disassembly and maintenance instructions established by the manufacturer must be followed.
If the formwork is not placed horizontally on the natural ground but inclined, mooring and unmooring by
means of cramps must be carried out using ladders. The tubular access ladder must meet the appropriate
safety requirements and it must be braced. The dismounting area must be duly protected.
It is forbidden to climb the formworks or balance oneself on them.
For assembly of panels the use of personal protective equipment is usually required to protect against the
risk of falls from a height; therefore certified harness hooks for fixed anchoring points available should be
used. In many cases these anchoring points are holes drilled on the ribs of the formworks which are
already secured.
Formwork panels must not be unhooked until they are properly stabilized. Stabilization of panels must be
carried out in accordance with their size and following the instructions of the manufacturer.
The use of struts and winches must be limited to those cases in which, due to space or other reasons, it
may not be possible to use stabilizers.
Before commencing works, the ground must be inspected to ensure good condition.
In case of sand storm, strong winds or very strong winds, works must be stopped.
Keep all work sites clean and ordered.
Rules for use and maintenance
176. It must be verified that all formworks are free from concrete and that all spikes have
been removed.
177. The crane operator must have a clear view throughout the whole operation. If that is not
possible, he or she must be assisted by a banksman.
178. During the placement of the formwork only those persons in charge of executing such an
operation can remain in the work area.
179. Correct strutting must be guaranteed.
180. Use appropriate walkways made with boards or other material with minimum thickness
of 60 cm in transit areas between nets and other materials.
181. Avoid premature formwork release.
182. Even distribution of the stockpiles of materials over the surfaces of the formwork.
183. Even distribution of the concrete.
184. The struts and the support systems must be inspected frequently.
185. The use of chemical products for formworks must be in accordance with the technical
specifications of the manufacturer as included in the technical data sheet.
186. Whenever possible, use machinery available for the transportation of the heaviest
elements of formwork; if this is not possible seek help from other workers.
187. During the striking process, if any panel of the formwork remains attached, it must be
removed, using a metallic lever, from an area where the formwork of which has already
removed.

6.4 FRAMEWORK

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188. The availability of stiffeners must be planned, with this assembly completed prior to the
placement frames. In the case of disassembly of frames, the process will proceed in the reverse
order or assembly, not removing stiffeners until frames have been removed.
189. The material to be placed on-site must be stored in the pit, classified by order of
assembly and in such a way that it does not hinder the normal progress of the activity. In the
event of excess in the pit, this will be separated from transit areas, as with any other product.
190. Work spotlights and lamps must not be installed directly above frames that are in
preparation or not put in place.
191. Standby vertical frames must be protected or signalled, in accordance with the
circumstances, where there is a risk of them falling.
192. Vertical slats of frames cannot be used as ladders for access to other work areas. Panels
or similar elements are recommended for walking on horizontal slats of frames.

6.5 MANIPULATION OF CONCRETE

193. Simultaneous work on two or more levels with mutual effect must always be avoided
where possible. It shall only be allowed in special cases subsequent to prior analysis if all
situations of risk that may arise and the appropriate provision of intermediate protection to
impede the transfer of risks caused by the simultaneous nature of activities. The design,
composition and placement of these protections must be subject to a specific study, to be
completed on-site and which must include instructions to proceed, the times of simultaneous
activities, communication codes etc.
194. Vehicles transporting concrete to the pit must approach with caution. It is recommended
that they be fitted with optical and acoustic control devices, synchronised in reverse to provide
warning of this manoeuvre.
195. Avoid contact of concrete with the skin.
196. In the case of the contact of cement or mortar with the eyes, wash them immediately
with clean water and request medical assistance.
197. Wash the surface skin that has been in contact with the cement of the mix (concrete,
mortar etc.).
198. In the case of allergies, apply protective cream and specific treatments.
199. In the case of accidental pouring, immediate recovery using suction systems is
recommended.
200. There is always a possibility of being knocked down by machines or vehicles, making it
necessary to carefully organize the circulation of these throughout the pit.

6.5.1 PUMPING OPERATIONS

201. The team responsible for managing pumping shall be made up of specialists in this task.
202. In pumping works, at the beginning smooth grout shall be used as a lubricant inside
pipes, for greater movement of material.
203. If during the pumping process, a blockage occurs, it shall be stopped to eliminate the
pressure to unblock it.
204. Periodic revision and maintenance of the pump and pipes and anchors.
205. Piping of concrete pumps must be overseen by at least two operators at a time to
prevent falls caused by uncontrolled movement.

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206. Before commencing concreting of a specific surface. A secure panelled walkway must be
laid for operators overseeing pouring with the hose.
207. The handling, assembly and disassembly of the concreting pump pipes must be directed
by a specialist operator to avoid accidents caused by blockages or excessive internal pressure.
208. Before commencing the pumping of concrete, the conduit must be prepared (greasing of
pipes) pumping doses of mortar and grout, to avoid blockages.
209. The ends of the hose are to be tied to prevent collisions caused by movement generated
by the pressure.
210. It is prohibited to add the cleaning ball without first installing the collection snood at the
mouth of the hose after a full circuit. If the ball becomes stuck, stop the machine. Pressure must
be reduced to zero so that the piping can be disassembled.
211. Operators will secure the hose terminal before initiating the ball process to clean solid
elements, moving away from the area once the process has been initiated.
212. The oil circuits of the concrete pump are to be checked periodically, in accordance with
the instructions manual.

6.5.2 POURING OPERATIONS USING A CHUTE.

213. Strong end-of-line stoppers will be installed on cement mixing trucks to avoid tipping.
214. As a general rule, it is prohibited for the wheels of concrete mixing trucks to approach
within 2 metres of the edge of the excavation.
215. When driving through the site, the sections of the chute must be removed.
216. It is prohibited to locate operators behind concrete mixing trucks during retreat.
217. Most of the pouring must be done by a Foreman who will ensure that no unsafe
manoeuvres are performed.

6.5.3 POURING OPERATIONS USING BUCKETS AND SKIPS

218. It is prohibited to load the skip above the maximum load of the crane which must bear it.
219. The area affected by the skip will be signalled.
220. The opening of the skip for pouring shall only be performed by pulling the corresponding
lever, with hands protected with impermeable gloves.
221. Fairleads must be used to assist in the correct positioning of the skip (or bucket) for the
pour. It is prohibited to guide or receive it directly, to prevent falls caused by the pendulum
movement of the skip.

6.5.4 PORTABLE CEMENT MIXERS


Aside from concrete transported in canisters, to cover small requirements on site, we must use fixed axle
or mobile concrete mixers which must fulfil the following conditions of safe use:
222. The barrel-blocking device must be checked periodically, as must the condition of lever
cables and accessories.
223. Upon completing the concrete mixer work, the operator must leave the barrel to rest on
the ground or in an elevated position, completely immobile.

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224. There concrete mixer is fitted with an earth connection, with all parts that may cause
trapping appropriately protected, the motor encased and the electrical panel insulated and
closed at all times.

6.6 MACHINERY
Pump Truck
Work vehicle and equipment that impulses, by means of a pump, concrete to areas separated from the
truck.

Concrete Mixer Truck


Piece of equipment that has a rotating tank mounted on the chassis, apt for the transport of concrete in
paste form.

6.6.1 GENERAL RULES

225. The truck is fitted with a rotating warning light or flash.


226. It must be fitted with an audible reverse warning signal.
227. When this vehicle is circulating through the site only, verify that the person driving is
authorized.
228. Ensure that Technical Inspections are kept up to date.
229. Guarantee communication between the driver and the Foreman at all times.
230. Before commencing work, check that all the devices of the pump truck are working
correctly and are in perfect conditions: brakes, tyres, lights etc.
231. Adjust seat and controls to an adequate position.

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232. Ensure maximum visibility in the pump truck, cleaning the wing mirrors, wipers and
mirrors.
233. Ensure that the cabin is clean, free from residues of oil, grease and mud and free of any
uncontrolled objects in the control area.
234. The driver must clean his footwear before using the access steps to the cabin.
235. Enter and exit the cabin only using the steps provided by the manufacturer. To enter and
exit the cabin, use two hands and always face the truck.
236. Check that all risk information readers are in good condition and are visible.
237. Check that the fire extinguisher is present in the truck.
238. Check the maximum height of the truck including the arms with the hose, is adequate to
avoid interference with different elements, electric lines etc.
239. Keep accesses, handles and steps clean.
240. The pump operator, where possible, must be able to see the pouring area and, if not,
must be assisted by signaller.
241. Do not load the barrel above the maximum load permitted.
242. Concrete mixers equipped with 90 cm or larger loading skips shall be equipped with a
mechanical device to clear the skip of material and shall have guardrails installed on each side of
the skip.
243. Concrete buckets equipped with hydraulic or pneumatically operated gates shall have
positive safety latches or similar safety devices installed to prevent premature or accidental
dumping. The buckets shall be designed to prevent material from accumulating on the top and
sides of the bucket.

6.6.2 RULES FOR USE AND MAINTENANCE

244. Workers and third parties must be prohibited from entering the operating range of the
machine.
245. Persons not involved in the activity must be prohibited from entering the area.
246. Do not enter or leave the truck while it is moving.
247. When driving, always use a retention system (cabin, seatbelt or similar). When on public
roads, the seatbelt is obligatory.
248. When recommencing an activity after rain, bear in mind that the conditions of the terrain
may have changed. Similarly, check that brakes are working correctly.
249. For operations close to electric cables, verify their voltage to establish a minimum
working distance.
250. If working visibility diminishes due to weather conditions or similar below the safety
limits, the vehicle must be parked in a secure spot to wait.
251. It is not permitted to descend hills with the motor stopped or engine left running.
252. Enter and exit the areas with precaution, if necessary with the help of a signaller.
253. Where operations require complex or dangerous manoeuvres, the operator must have
the support of an expert signaller to guide them.
254. Maintain permanent visual contact with work teams in movement and workers in the
work area.
255. You must respect the internal signalling of the site.
256. When moving the pump truck to in areas within 2 m of the edge of embankments.

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257. If required to work in enclosed spaces, ensure that ventilation is sufficient or gases have
been extracted.
258. Before commencing pumping of concrete, check that the wheels are blocked with
wedges and mechanical or hydraulic stabilizers.
259. Clean the interior of the tubes of all the equipment once the work has been completed
and do so in areas designed to hold residual water.
260. In cases of proximity to electrical lines, locate a height limitation gantry.
261. For pumping operations, the truck must be situated on a perfectly level surface, using
stabilizing jacks on the ground.
262. An employee who has a good knowledge of giving the correct signals to warn employees
on site when concrete transit mixers are moving reverse and the direction of the discharge box,
also to guide the truck operator.
263. The routes designated for the reverse movement of the concrete trucks shall be free of
any equipment, debris and workers.
264. The pumping area must remain completely isolated from pedestrians.
265. Check that for pressures greater than 50 bars on concrete the following conditions and
controls are met: that pressure tubes specified by the manufacturer for a specific case are fitted;
that a test is carried out to ensure pressure is at 30% above pressure for normal service; that
stockpiles, joints and elbows are checked and changed where necessary (every 1000 m3
pumped).
266. Before proceeding with pumping, check that all transport tube couplings and elbows are
perfectly leak proof.
267. Avoid touching or placing your hands inside the interior of the rotating tube chute when
the equipment is turned on.
268. The pumping equipment safety devices must always be in perfect working conditions.
Any modification or poor handling is expressly prohibited.
269. Do not exceed the gradients established by the instruction manual.
270. For maintenance operations do not wear loose clothing or jewellery and use the
appropriate protection equipment.
271. For maintenance operations the machine must be parked on flat ground, the parking
brake connected, the transmission in neutral, the motor stopped and the battery switch in the
disconnected position.
272. Carry out repair tasks on the truck with the motor stopped and the vehicle parked.
273. Residues generated as a consequence of a breakdown or its repair must be segregated in
containers.
274. Park the pump truck in appropriate areas, on flat firm ground with no risk of sinking,
landslide or flooding ( a minimum of 2 m from the edge of embankments). You must put on the
brakes, remove the keys from the ignitions, turn off the battery switch and close the cabin and
bonnet.

6.7 AUXILIARY EQUIPMENT

6.7.1 CONCRETE VIBRATOR


Piece of work equipment that, through vibration, is used to homogenize poured concrete for concrete
structures.

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General Rules
275. Specific training in the use of this equipment is required.
276. Follow the manufacturer's instructions.
Rules for Use and Maintenance
277. Before starting work, clean any possible oil or fuel leaks.
278. Check periodically that the earth connection is working correctly.
279. Check that the needle is not caught in the frames.
280. Vibration must be performed from a stable position, on work platforms.
281. It is prohibited to work in adverse weather conditions: strong winds and rain.
282. Ensure transit areas are free of electrical cables.
283. They must be repaired by qualified personnel.
284. The connection or electrical supply must be made using moisture-proof multicore cable.
285. Cleaning and maintenance operations must be done with the electrical system
disconnected.
286. Do not leave the machine unattended when functioning.
287. Do not allow the vibrator to work in a vacuum.
288. Worn or cracked tools must be replaced immediately.

6.7.2 BUCKET
Work equipment consisting of a container filled with concrete and guided by a crane, allowing for the
concreting of difficult-to-reach areas or transport of other materials there.

Rules for use and maintenance

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289. Avoid filling the bucket to the limits of where any imbalance caused by the crane might
cause spillage.
290. Adapt the load of the bucket to the maximum weight the crane can lift.
291. In situations of strong winds or very strong winds, works must be stopped.
292. Periodically revise the area and the connected section and outlet for concrete, ensuring
the are no leaks in the transport process.
293. Avoid manoeuvres involving abrupt movement of the bucket.
294. The load must be transported with the elevated bucket and it cannot be unchained until
it has reached the pouring point to allow for unloading.
295. At the pouring point, the bucket must be unchained vertically to avoid collision with
operators.

7 RELATED DOCUMENTS

296. 18002-HSE-TI-007-00 HSE induction presentation


297. 18002-HSE-MG-017-0 Permit to work management.
298. 18002-HSE-MG-013-00 HSE Signposting
299. 18002-HSE-MG-007-00 HSE Training
300. 18002-HSE-MG-011-00 HSE Inspections
301. 18002-HSE-MG-010-00 House keeping
302. 18002-HSE-MG-024-00 Management of vehicles, plant, machinery and tools
303. 18002-HSE-PL-001-00 HSE Management plan

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